Storage and retrieval system

ABSTRACT

In accordance with one or more aspects of the disclosed embodiment, a lift includes at least one load handling device configured so as to reciprocate along a lift axis, the load handling device including a frame forming a payload section with a payload support surface having a common elevation configured to hold one or more pickfaces at the common elevation of the payload support surface, at least one transfer arm movably mounted to the frame, and a drive section connected to the load handling device and being configured to move the load handling device along the lift axis, wherein the one or more pickfaces carried in unison by the payload support surface of the at least one load handling device, define an order sequence of pickfaces on the at least one load handling device according to a predetermined case out order sequence of mixed cases.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Application No. 16/284,930,filed Feb. 25, 2019, (now U.S. Pat. No. 10,954,066), which is acontinuation of U.S. Non-Provisional Patent Application No. 14/997,902,filed on Jan. 18, 2016, (now U.S. Pat. No. 10,214,355, issued Feb. 26,2019), which claims priority and benefit from U.S. Provisional PatentApplication No. 62/104,552, filed on Jan. 16, 2015, the disclosures ofwhich are incorporated by reference herein in their entireties.

This application is also related to U.S. patent application Ser. No.14/966,978 filed on Dec. 11, 2015; U.S. patent application Ser. No.14/997,892, filed Jan. 15, 2016; U.S. patent application Ser. No.14/997,925, filed Jan. 15, 2016; U.S. patent application Ser. No.14/997,920, filed Jan. 15, 2016; and U.S. Provisional Patent ApplicationNo. 62/107,135, filed on Jan. 23, 2015, the disclosures of which areincorporated herein by reference in their entireties.

BACKGROUND 1. Field

The exemplary embodiments generally relate to material handling systemsand, more particularly, to transport and storage of items within thematerial handling system.

2. Brief Description of Related Developments

Multilevel storage and retrieval systems may be used in warehouses forthe storage and retrieval of goods. Generally the transportation ofgoods into and out of the storage structure is done with lifts fortransfer to a vehicle on a storage level, vehicles travelling up rampsto a predetermined storage level, or with vehicles that include liftstraveling along guide ways. Goods stored within the storage andretrieval system are generally stored in storage spaces on each storagelevel such that a transport vehicle disposed on that level has access toone level of storage spaces. Generally, the lifts that transfer items toand from the storage spaces carry the vehicles between different storagelevels, are incorporated into the vehicles (such as with a gantry crane)or have a paternoster configuration where the lift payload shelvescontinually circulate around a frame at a predetermined rate.

It would be advantageous to increase a rate of item transfer to and fromthe different storage levels within a storage and retrieval systemindependent of the transfer vehicles that deliver the items to thestorage spaces.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodiment areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem in accordance with aspects of the disclosed embodiment;

FIG. 1A is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 1B is a schematic illustration of a portion of the automatedstorage and retrieval system in accordance with aspects of the disclosedembodiment;

FIG. 2 is a schematic illustration of a mixed pallet load formed by theautomated storage and retrieval system in accordance with aspects of thedisclosed embodiment;

FIGS. 3A and 3B are schematic illustrations of portions of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 4A and 4B are schematic illustrations of portions of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 5A, 5B, 5C, 5D, 5E, 5F and 5G are schematic illustrations ofportions of the storage and retrieval system in accordance with aspectsof the disclosed embodiment;

FIG. 6 is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIG. 6A is a schematic illustration of a portion of the storage andretrieval system in accordance with aspects of the disclosed embodiment;

FIGS. 7, 7A-7E are schematic illustrations of a portion of the storageand retrieval system in accordance with aspects of the disclosedembodiment;

FIGS. 8-15 are flow diagrams in accordance with aspects of the disclosedembodiment;

FIG. 16 is a schematic illustration of an operator station of thestorage and retrieval system in accordance with aspects of the disclosedembodiment; and

FIG. 17 is an exemplary flow diagram in accordance with aspects of thedisclosed embodiment.

DETAILED DESCRIPTION

FIG. 1 is a schematic illustration of an automated storage and retrievalsystem 100 in accordance with aspects of the disclosed embodiment.Although the aspects of the disclosed embodiment will be described withreference to the drawings, it should be understood that the aspects ofthe disclosed embodiment can be embodied in many forms. In addition, anysuitable size, shape or type of elements or materials could be used.

In accordance with aspects of the disclosed embodiment the automatedstorage and retrieval system 100 may operate in a retail distributioncenter or warehouse to, for example, fulfill orders received from retailstores for case units such as those described in U.S. patent applicationSer. No. 13/326,674 filed on Dec. 15, 2011, the disclosure of which isincorporated by reference herein in its entirety. For example, the caseunits are cases or units of goods not stored in trays, on totes or onpallets (e.g. uncontained). In other examples, the case units are casesor units of goods that are contained in any suitable manner such as intrays, on totes or on pallets. In still other examples, the case unitsare a combination of uncontained and contained items. It is noted thatthe case units, for example, include cased units of goods (e.g. case ofsoup cans, boxes of cereal, etc.) or individual goods that are adaptedto be taken off of or placed on a pallet. In accordance with the aspectsof the disclosed embodiment, shipping cases for case units (e.g.cartons, barrels, boxes, crates, jugs, or any other suitable device forholding case units) may have variable sizes and may be used to hold caseunits in shipping and may be configured so they are capable of beingpalletized for shipping. It is noted that when, for example, bundles orpallets of case units arrive at the storage and retrieval system thecontent of each pallet may be uniform (e.g. each pallet holds apredetermined number of the same item—one pallet holds soup and anotherpallet holds cereal) and as pallets leave the storage and retrievalsystem the pallets may contain any suitable number and combination ofdifferent case units (e.g. a mixed pallet where each mixed pallet holdsdifferent types of case units—a pallet holds a combination of soup andcereal) that are provided to, for example the palletizer in a sortedarrangement for forming the mixed pallet. In the embodiments the storageand retrieval system described herein may be applied to any environmentin which case units are stored and retrieved.

Also referring to FIG. 2, it is noted that when, for example, incomingbundles or pallets (e.g. from manufacturers or suppliers of case unitsarrive at the storage and retrieval system for replenishment of theautomated storage and retrieval system 100, the content of each palletmay be uniform (e.g. each pallet holds a predetermined number of thesame item—one pallet holds soup and another pallet holds cereal). As maybe realized, the cases of such pallet load may be substantially similaror in other words, homogenous cases (e.g. similar dimensions), and mayhave the same SKU (otherwise, as noted before the pallets may be“rainbow” pallets having layers formed of homogeneous cases). As palletsPAL leave the storage and retrieval system 100, with cases fillingreplenishment orders, the pallets PAL may contain any suitable numberand combination of different case units CU (e.g. each pallet may holddifferent types of case units—a pallet holds a combination of cannedsoup, cereal, beverage packs, cosmetics and household cleaners). Thecases combined onto a single pallet may have different dimensions and/ordifferent SKU's. In one aspect of the exemplary embodiment, the storageand retrieval system 100 may be configured to generally include anin-feed section, a storage and sortation section (where, in one aspect,storage of items is optional) and an output section as will be describedin greater detail below. As may be realized, in one aspect of thedisclosed embodiment, the system 100 operating for example as a retaildistribution center may serve to receive uniform pallet loads of cases,breakdown the pallet goods or disassociate the cases from the uniformpallet loads into independent case units handled individually by thesystem, retrieve and sort the different cases sought by each order intocorresponding groups, and transport and assemble the correspondinggroups of cases into what may be referred to as mixed case pallet loadsMPL. As may also be realized, as illustrated in FIG. 16, in one aspectof the disclosed embodiment the system 100 operating for example as aretail distribution center may serve to receive uniform pallet loads ofcases, breakdown the pallet goods or disassociate the cases from theuniform pallet loads into independent case units handled individually bythe system, retrieve and sort the different cases sought by each orderinto corresponding groups, and transport and sequence the correspondinggroups of cases (in the manner described herein) at an operator station160EP where items are picked from the different case units CU, and/orthe different case units CU themselves, are placed in one or morebag(s), tote(s) or other suitable container(s) TOT by an operator 1500,or any suitable automation, in a predetermined order sequence of pickeditems according to, for example, an order, fulfilling one or morecustomer orders, in which the case units CU are sequenced at theoperator station 160EP in accordance with the predetermined ordersequence, noting that the sequencing of the case units CU as describedherein effects the sequencing of the case units CU at the operatorstation 160EP.

The in-feed section may generally be capable of resolving the uniformpallet loads to individual cases, and transporting the cases viasuitable transport, for input to the storage and sortation section. Thestorage and sortation section in one aspect receives individual cases,stores them in a storage area and retrieves desired cases individuallyin accordance with commands generated in accordance to orders enteredinto a warehouse management system for transport to the output section.In other aspects, the storage and sortation section receives individualcases, sorts the individual cases (utilizing, for example, the bufferand interface stations described herein) and transfers the individualcases to the output section in accordance to orders entered into thewarehouse management system. The sorting and grouping of cases accordingto order (e.g. an order out sequence) may be performed in whole or inpart by either the storage and retrieval section or the output section,or both, the boundary between being one of convenience for thedescription and the sorting and grouping being capable of beingperformed any number of ways. The intended result is that the outputsection assembles the appropriate group of ordered cases, that may bedifferent in SKU, dimensions, etc. into, in one aspect, mixed casepallet loads in the manner described in, for example, U.S. patentapplication Ser. No. 13/654,293 filed on Oct. 17, 2012, (now U.S. Pat.No. 8,965,559) the disclosure of which is incorporated herein byreference in its entirety, while in other aspects the output sectionassembles the appropriate group of ordered case units, that may bedifferent in SKU, dimensions, etc. into bags, totes or other suitablecontainers according to the predetermined order sequence of picked itemsat the operator station 160E (such as to fill e.g., a customer order).

In one aspect of the exemplary embodiment, the output section generatesthe pallet load in what may be referred to as a structured architectureof mixed case stacks. The structured architecture of the pallet loaddescribed herein is representative and in other aspects the pallet loadmay have any other suitable configuration. For example, the structuredarchitecture may be any suitable predetermined configuration such as atruck bay load or other suitable container or load container envelopeholding a structural load. The structured architecture of the palletload may be characterized as having several flat case layers L121-L125,L12T, at least one of which is formed of non-intersecting, free-standingand stable stacks of multiple mixed cases. The mixed case stacks of thegiven layer have substantially the same height, to form as may berealized substantially flat top and bottom surfaces of the given layer,and may be sufficient in number to cover the pallet area, or a desiredportion of the pallet area. Overlaying layer(s) may be orientated sothat corresponding cases of the layer(s) bridge between the stacks ofthe supporting layer. Thus, stabilizing the stacks and correspondinglythe interfacing layer(s) of the pallet load. In defining the pallet loadinto a structured layer architecture, the coupled 3-D pallet loadsolution is resolved into two parts that may be saved separately, avertical (1-D) part resolving the load into layers, and a horizontal(2-D) part of efficiently distributing stacks of equal height to fillout the pallet height of each layer. In other aspects the load fill ofmixed cases may be configured in any other suitable ordered sequence andmay be loaded on or in any suitable transport device such as, forexample, a bag, tote, shopping carriage, a truck or other suitablecontainer fill without palletization. As will be described below, thestorage and retrieval system outputs case units to the output section sothat the two parts of the 3-D pallet load solution are resolved, whilein other aspects the storage and retrieval system outputs case units tothe output section according to a sequence for filling non-palletizeditem picking sequence orders at the operator station 160EP. Thepredetermined structure of the mixed pallet load defines an order ofcase units, whether the case units are a singular case unit pickface ora combined case unit pickface provided by the sortation and outputsections to a load construction system (which may be automated or manualloading). The term load fill or container fill as used herein refers tocase units that are delivered to either a pallet load fill section/cell(such as for the creation of a mixed pallet load MPL) or an itemizedload fill section/cell as described with respect to FIG. 16 where boththe pallet load fill section/cell and the itemized load fillsection/cell are referred to generally as load fill section/station orcell.

In accordance with aspects of the disclosed embodiment, referring againto FIG. 1, the automated storage and retrieval system 100 includes inputstations 1601N (which include depalletizers 160PA, operator stations160EP and/or conveyors 160CA for transporting items to lift modules forentry into storage) and output stations 16OUT (which include palletizers160PB and/or conveyors 160CB for transporting case units from liftmodules for removal from storage), input and output vertical liftmodules 150A, 150B (generally referred to as lift modules 150—it isnoted that while input and output lift modules are shown, a single liftmodule may be used to both input and remove case units from the storagestructure), a storage structure 130, and a number of autonomoustransport vehicles 110 (referred to herein as “bots”). As used hereinthe lift modules 150, storage structure 130 and bots 110 may becollectively referred to herein as the storage and sorting section notedabove. It is also noted that the depalletizers 160PA may be configuredto remove case units from pallets so that the input station 1601N cantransport the items to the lift modules 150 for input into the storagestructure 130. The palletizers 160PB may be configured to place itemsremoved from the storage structure 130 on pallets PAL (FIG. 2) forshipping.

Also referring to FIG. 3A, the storage structure 130 may includemultiple storage rack modules RM, configured in a three dimensionalarray RMA, that are accessible by storage or deck levels 130L. Eachstorage level 130L includes pickface storage/handoff spaces 130S(referred to herein as storage spaces 130S) formed by the rack modulesRM where the rack modules include shelves that are disposed alongstorage or picking aisles 130A which, e.g., extend linearly through therack module array RMA and provide access to the storage spaces 130S andtransfer deck(s) 130B over which the bots 110 travel on a respectivestorage level 130L for transferring case units between any of thestorage spaces 130S of the storage structure 130 (e.g. on the levelwhich the bot 110 is located) and any of the lift modules 150 (e.g. eachof the bots 110 has access to each storage space 130S on a respectivelevel and each lift module 150 on a respective storage level 130L). Thetransfer decks 130B are arranged at different levels (corresponding toeach level 130L of the storage and retrieval system) that may be stackedone over the other or horizontally offset, such as having one transferdeck 130B at one end or side RMAE1 of the storage rack array RMA or atseveral ends or sides RMAE1, RMAE2 of the storage rack array RMA asdescribed in, for example, U.S. patent application Ser. No. 13/326,674filed on Dec. 15, 2011 the disclosure of which is incorporated herein byreference in its entirety.

The transfer decks 130B are substantially open and configured for theundeterministic traversal of bots 110 across and along the transferdecks 130B. As may be realized, the transfer deck(s) 130B at eachstorage level 130L communicate with each of the picking aisles 130A onthe respective storage level 130L. Bots 110 bi-directionally traversebetween the transfer deck(s) 130B and picking aisles 130A on eachrespective storage level 130L to access the storage spaces 130S disposedin the rack shelves alongside each of the picking aisles 130A (e.g. bots110 may access storage spaces 130S distributed on both sides of eachaisle such that the bot 110 may have a different facing when traversingeach picking aisle 130A, for example, referring to FIG. 3B, drive wheels202 leading a direction of travel or drive wheels trailing a directionof travel). As noted above, the transfer deck(s) 130B also provide bot110 access to each of the lifts 150 on the respective storage level 130Lwhere the lifts 150 feed and remove case units to and/or from eachstorage level 130L and where the bots 110 effect case unit transferbetween the lifts 150 and the storage spaces 130S. As described above,referring also to FIG. 3A, in one aspect the storage structure 130includes multiple storage rack modules RM, configured in a threedimensional array RMA where the racks are arranged in aisles 130A, theaisles 130A being configured for bot 110 travel within the aisles 130A.The transfer deck 130B has an undeterministic transport surface on whichthe bots 100 travel where the undeterministic transport surface 130BShas more than one juxtaposed travel lane (e.g. high speed bot travelpaths HSTP) connecting the aisles 130A. As may be realized, thejuxtaposed travel lanes are juxtaposed along a common undeterministictransport surface 130BS between opposing sides 130BD1, 130BD2 of thetransfer deck 130B. As illustrated in FIG. 3A, in one aspect the aisles130A are joined to the transfer deck 130B on one side 130BD2 of thetransfer deck 130B but in other aspects, the aisles are joined to morethan one side 130BD1, 130BD2 of the transfer deck 130B in a mannersubstantially similar to that described in U.S. patent application Ser.No. 13/326,674 filed on Dec. 15, 2011, the disclosure of which ispreviously incorporated by reference herein in its entirety. As will bedescribed in greater detail below the other side 130BD1 of the transferdeck 130B includes deck storage racks (e.g. interface stations TS andbuffer stations BS) that are distributed along the other side 130BD1 ofthe transfer deck 130B so that at least one part of the transfer deck isinterposed between the deck storage racks and the aisles 130A. The deckstorage racks are arranged along the other side 130BD1 of the transferdeck 130B so that the deck storage racks communicate with the bots 110from the transfer deck 130B and with the lift modules 150 (e.g. the deckstorage racks are accessed by the bots 110 from the transfer deck 130Band by the lifts 150 for picking and placing pickfaces so that pickfacesare transferred between the bots 110 and the deck storage racks andbetween the deck storage racks and the lifts 150 and hence between thebots 110 and the lifts 150).

Each storage level 130L may also include charging stations 130C forcharging an on-board power supply of the bots 110 on that storage level130L such as described in, for example, U.S. patent application Ser. No.14/209,086 filed on Mar. 13, 2014 and Ser. No. 13/326,823 filed on Dec.15, 2011, (now U.S. Pat. No. 9,082,112) the disclosures of which areincorporated herein by reference in their entireties.

The bots 110 may be any suitable independently operable autonomoustransport vehicles that carry and transfer case units throughout thestorage and retrieval system 100. In one aspect the bots 110 areautomated, independent (e.g. free riding) autonomous transport vehicles.Suitable examples of bots can be found in, for exemplary purposes only,U.S. patent application Ser. No. 13/326,674 filed on Dec. 15, 2011; U.S.patent application Ser. No. 12/757,312 filed on Apr. 9, 2010, (now U.S.Pat. No. 8,425,173); U.S. patent application Ser. No. 13/326,423 filedon Dec. 15, 2011; U.S. patent application Ser. No. 13/326,447 filed onDec. 15, 2011, (now U.S. Pat. No. 8,965,619); U.S. patent applicationSer. No. 13/326,505 Dec. 15, 2011, (now U.S. Pat. No. 8,696,010); U.S.patent application Ser. No. 13/327,040 filed on Dec. 15, 2011, (now U.S.Pat. No. 9,187,244); U.S. patent application Ser. No. 13/326,952 filedon Dec. 15, 2011; U.S. patent application Ser. No. 13/326,993 filed onDec. 15, 2011; U.S. patent application Ser. No. 14/486,008 filed on Sep.15, 2014; and U.S. Provisional Patent Application No. 62/107,315 filedon Jan. 23, 2015 the disclosures of which are incorporated by referenceherein in their entireties. The bots 110 (described in greater detailbelow) may be configured to place case units, such as the abovedescribed retail merchandise, into picking stock in the one or morelevels of the storage structure 130 and then selectively retrieveordered case units.

The bots 110, lift modules 150 and other suitable features of thestorage and retrieval system 100 are controlled in any suitable mannersuch as by, for example, one or more central system control computers(e.g. control server) 120 through, for example, any suitable network180. In one aspect the network 180 is a wired network, a wirelessnetwork or a combination of wireless and wired networks using anysuitable type and/or number of communication protocols. In one aspect,the control server 120 includes a collection of substantiallyconcurrently running programs (e.g. system management software) forsubstantially automatic control of the automated storage and retrievalsystem 100. The collection of substantially concurrently runningprograms, for example, being configured to manage the storage andretrieval system 100 including, for exemplary purposes only,controlling, scheduling, and monitoring the activities of all activesystem components, managing inventory (e.g. which case units are inputand removed, the order in which the cases are removed and where the caseunits are stored) and pickfaces (e.g. one or more case units that aremovable as a unit and handled as a unit by components of the storage andretrieval system), and interfacing with a warehouse management system2500. The control server 120 may, in one aspect, be configured tocontrol the features of the storage and retrieval system in the mannerdescribed herein. For simplicity and ease of explanation the term “caseunit(s)” is generally used herein for referring to both individual caseunits and pickfaces (formed of one or multiple case units). In oneaspect, as will be described herein the control server 120 is connectedto the lift modules 150 for controlling the lift modules 150 asdescribed herein. In other aspects the lift modules 150 include a liftcontroller LCM connected to the control server 120 where one or more ofthe lift controller LCM and the control server 120 control the liftmodules as described herein. In one aspect, one or more of the liftcontroller LCM and the control server 120 are configured to control thelift modules 150 to effect picking more than one pickface with thecommon payload support platform, and an on-the-fly sortation of the morethan one pickface with the common payload support platform as describedherein. In one aspect, one or more of the lift controller LCM and thecontrol server 120 is configured to control the lift modules 150 toeffect picking of the more than one pickface, with the common payloadsupport platform, in an ordered sequence and placing the one or morepickfaces, with the common payload support platform, in the orderedsequence at an outbound pickface holding location as described herein.In one aspect one or more of the lift controller LCM and the controlserver 120 is configured to control the lift modules 150 to effect theon-the-fly sortation of the more than one pickface where the commonpayload support platform traverses a stack of pickface holding locationsin a common direction as described herein. In one aspect one or more ofthe lift controller LCM and the control server 120 is configured tocontrol the lift modules 150 to effect placement of more than onepickface at an outbound pickface holding location in one offload step,where the more than one pickface has a sorted arrangement at offload asdescribed herein.

Referring also to FIGS. 1A and 1B the rack module array RMA of thestorage structure 130 includes vertical support members 1212 andhorizontal support members 1200 that define a high density automatedstorage array such as described in, for example, U.S. patent applicationSer. No. 14/966,978, filed Jan. 15, 2016 and U.S. Provisional PatentApplication No. 62/104,513 filed on Jan. 16, 2015, the disclosures ofwhich are incorporated herein by reference in their entireties. Rails1200S may be mounted to one or more of the vertical and horizontalsupport members 1212, 1200 in, for example, picking aisles 130A and beconfigured so that the bots 110 ride along the rails 1200S through thepicking aisles 130A. At least one side of at least one of the pickingaisles 130A of at least one storage level 130L may have one or morestorage shelves (e.g. formed by rails 1210, 1200 and slats 1210S)provided at differing heights so as to form multiple shelf levels130LS1-130LS2 (although two levels are illustrated any number of levelsmay be provided and the picking aisle can be divided into sections SECA,SECB each having a different number of levels or the same number oflevels) between the storage or deck levels 130L defined by the transferdecks 130B (and the rails 1200S which form an aisle deck). Accordingly,there are multiple rack shelf levels 130LS1-130LS2, corresponding toeach storage level 130L, extending along one or more picking aisles 130Acommunicating with the transfer deck 130B of the respective storagelevel 130L. As may be realized, the multiple rack shelf levels130LS1-130LS2 effect each storage level 130L having stacks of storedcase units (or case layers) that are accessible from a common deck 1200Sof a respective storage level 130L (e.g. the stacks of stored cases arelocated between storage levels). In one aspect, referring to FIG. 1Beach of the storage levels 130L includes a single level of storageshelves to store a single level of case units (e.g. each storage levelincludes a single case unit support plane CUSP) and the bots 110 areconfigured to transfer case units to and from the storage shelves of therespective storage level 130L.

As may be realized, bots 110 traversing a picking aisle 130A, at acorresponding storage level 130L, have access (e.g. for picking andplacing case units) to each storage space 130S that is available on eachshelf level 130LS1-130LS2, where each shelf level 130LS1-130LS2 islocated between the storage levels 130L on one or more side(s) PAS1,PAS2 (see e.g. FIG. 3A) of the picking aisle 130A. As noted above, eachof the storage shelf levels 130LS1-130LS2 is accessible by the bot 110from the rails 1200S (e.g. from a common picking aisle deck 1200S thatcorresponds with a transfer deck 130B on a respective storage level130L). As can be seen in FIG. 1A there are one or more shelf rails 1210vertically spaced (e.g. in the Z direction) from one another to formmultiple stacked storage spaces 130S each being accessible by the bot110 from the common rails 1200S. As may be realized, the horizontalsupport members 1200 also form shelf rails (in addition to shelf rails1210) on which case units are placed. Here the bots 110 includes atransfer arm 110PA having a vertical drive axis configured to transfercase units to each of the shelf levels 130LS1-130LS2 from the commonpicking aisle deck. A suitable example of bot that services multipleshelf levels from a common picking aisle deck can be found in, forexample, U.S. patent application Ser. No. 14/997,892, filed Jan. 15,2016 and U.S. Provisional Patent Application No. 62/104,513, filed onJan. 16, 2015, the disclosures of which are incorporated herein byreference in their entireties. In other aspects, where each storagelevel 130L includes a single level of storage shelves as illustrated inFIG. 1B the bot, such as bot 110′ (which is substantially similar to bot110), is not provided with sufficient Z-travel of the transfer arm 110PAfor placing case units on the multiple storage shelf levels130LS1-130LS2 (e.g. accessible from a common rail 1200S) as describedabove. Here the transfer arm drive of the bots 110′ includes onlysufficient Z-travel for lifting the case units from the case unitsupport plane CUSP of the single level of storage shelves, fortransferring the case units to and from the payload area 110PL and fortransferring the case units between the transfer arm 110PA and thepayload bed 110PB of the payload area 110PL. Suitable examples of bots110′ can be found in, for example, U.S. patent application Ser. No.13/326,993 filed on Dec. 15, 2011, the disclosure of which isincorporated herein by reference in its entirety.

Each stacked shelf level 130LS1-130LS2 (and/or each single shelf level)of a corresponding storage level 130L defines an open andundeterministic two dimensional storage surface (e.g. having a case unitsupport plane CUSP as shown in FIG. 1A) that facilitates a dynamicallocation of pickfaces both longitudinally (e.g. along a length theaisle or coincident with a path of bot travel defined by the pickingaisle) and laterally (e.g. with respect to rack depth, transverse to theaisle or the path of bot travel). Dynamic allocation of the pickfacesand case units that make up the pickfaces is provided, for example, inthe manner described in U.S. patent application Ser. No. 12/757,337,(now U.S. Pat. No. 8,594,835), the disclosure of which is incorporatedby reference herein in its entirety. As such, case unit (or tote)pickfaces of variable lengths and widths are positioned at each twodimensional storage location on the storage shelves (e.g. on eachstorage shelf level 130LS1-130LS2) with minimum gaps (e.g. that effectpicking/placing of case units free from contact with other case unitsstored on the shelves) between adjacent stored case units/storagespaces. In one aspect, the storage space(s) 130S defined by the storageshelf levels 130LS1-130LS2 between the storage or deck levels 130Laccommodates case units of different heights, lengths, widths and/orweights at the different shelf levels 130LS1-130LS2 as described in, forexample, U.S. patent application Ser. No. 14/966,978, filed on Dec. 11,2015 and U.S. Provisional Patent Application No. 62/091,162 filed onDec. 12, 2014, the disclosures of which are incorporated by referenceherein in their entireties.

Referring again to FIG. 3A each transfer deck or storage level 130Lincludes one or more lift pickface interface/handoff stations TS(referred to herein as interface stations TS) where case unit(s) (ofsingle or combined case pickfaces) or totes are transferred between thelift load handling devices LHD and bots 110 on the transfer deck 130B.The interface stations TS are located at a side of the transfer deck130B opposite the picking aisles 130A and rack modules RM, so that thetransfer deck 130B is interposed between the picking aisles and eachinterface station TS. As noted above, each bot 110 on each picking level130L has access to each storage location 130S, each picking aisle 130Aand each lift 150 on the respective storage level 130L, as such each bot110 also has access to each interface station TS on the respective level130L. In one aspect the interface stations are offset from high speedbot travel paths HSTP along the transfer deck 130B so that bot 110access to the interface stations TS is undeterministic to bot speed on ahigh speed travel path HSTP. As such, each bot 110 can move a caseunit(s) (or pickface, e.g. one or more cases, built by the bot) fromevery interface station TS to every storage space 130S corresponding tothe deck level and vice versa.

As an example, in one aspect, the pickface, built by the bot 110 (e.g.in the manner described above), that is transferred to (e.g. placed to),for example, the interface station TS (and/or buffer station BS) is notthe same pickface that is picked from the interface station TS (and/orbuffer station BS) by the lift 150. For example, referring to FIG. 6,the bot 110 builds a first pickface from the storage spaces 130S withinthe rack modules RM (e.g. FIG. 3A) and/or buffers BS on the transferdeck 130B that includes individual pickfaces 7 and (FIG. 14, Block1900). The bot 110 transfers the first pickface to and places the firstpickface on, for example, shelf 7000B of interface station TS fortransfer to a lift 150 (FIG. 14, Block 1910). As may be realized, whilein this example, the individual pickfaces 5, 7 (e.g. forming the firstpickface) are placed on a common shelf 7000B for exemplary purposesonly, in other aspects the individual pickfaces 5, 7 are placed ondifferent shelves 7000A-7000F so that the pickface placed on the shelvesby the bot 110 is different than the first pickface but includes atleast one case unit in common with the first pickface. For example, thefirst pickface is broken up such that a different pickface includingindividual pickface 5 is placed on shelf 7000B while another differentpickface including individual pickface 7 is placed on, for example,shelf 7000H. A lift, such as lift 150B1 picks a second pickface from oneor more shelves 7000A-7000F (e.g. common to both the bot 110 and thelift 150B1) of the transfer stations TS (FIG. 14, Block 1920). Here thesecond pickface is different than the first pickface but includes atleast one of the individual pickfaces 5, 7 so that at least one caseunit is common between the first pickface and the second pickface.

Similarly, in one aspect, the pickface that is transferred to (e.g.placed to), for example, the interface station TS (and/or buffer stationBS) by the inbound lift 150 (see lift 150A in FIG. 1) is not the samepickface that is picked from the interface station TS (and/or bufferstation BS) by the bot 110. In one aspect, the control server 120 isconfigured to command the bot 110, and effect with the bot 110 inboundflow (which may also be referred to as warehouse replenishment orinbound stream(s)) case sortation at a handoff station TS (and/or bufferstation BS) with the bot 110 forming a pickface, independent of the pickorder of cases from an input station by the lift 150. In one aspect, thebot controller 110C is configured to command the bot 110, and effectwith the bot 110 inbound flow case sortation at the handoff station TS(and/or buffer station BS) with the bot 110 forming the pickface,independent of the pick order of cases from an input station by the lift150. In still other aspects, the control server 120 and the botcontroller 110C are both configured to command the bot 110, and effectwith the bot 110 inbound flow case sortation at the handoff stations TS(and/or buffer station BS) with the bot 110 forming the pickface,independent of the pick order of cases from an input station by the lift150. Thus, the control server 120 and/or the bot controller 110C is/areconfigured to set the inbound case flow, at least in part with bot 110sortation of the cases carried in common by the both 110 and decoupledfrom the pick order of the cases by the lift 150. This may be referredto for description purposes as inbound flow case sortation with the bot110 at the handoff station TS (and/or buffer station BS). For example,referring to FIG. 6A, first pickfaces are transferred to one or morelifts 150A1, 150A2 from the input station(s) 1601N by the inboundconveyors 160CB, i.e., the lifts 150A1, 150A2 each pick a first pickface(FIG. 15, Block 2000). In this example, one of the first pickfaces, suchas the first pickface picked by lift 150A1, includes a combination ofindividual pickfaces 5, 7 while the other first pickface, picked by lift150A2, includes a combination of individual pickfaces 20, 22. The lifts150 may effect sorting of the inbound case flow by placing one or morepickfaces held on a common shelf of the lift at a first interfacestation and retaining other case units on the common shelf of the liftfor placement at another different interface station. For example, thelift 150A1 places the respective first pickface 5, 7 to shelf 7000B ofinterface station TS while lift 150A2 places the other respective firstpickface 20, 22 to shelf 7000H of another interface station TS on thesame storage level 130L (FIG. 15, Block 2010). In other aspects, thefirst pickface 5, 7 may be broken up into at least a second pickfacewhere pickface 5 (e.g. the second pickface) may be placed on shelf 7000Bwhile pickface 7 (e.g. a third pickface) is placed on shelf 7000D (FIG.15, Block 2015). In one aspect, the lifts 150 may transfer one or morecase units from one storage level to another, such as from shelf 7000Ato shelf 7000D where a bot 110 picks the transferred case units(transferred from the storage level corresponding to shelf 7000A) andplaces the transferred case units in storage spaces on the storage levelcorresponding shelf 7000D. The bot 110 builds or otherwise picks asecond pickface(s) from the interface station(s) TS so that the firstpickface(s) placed on the shelf(s) 7000B, 7000H (e.g. common to both thebot 110 and a respective lift 150A) by the lifts 150A1, 150A2 is/aredifferent than the second pickface but the second pickface includes atleast one case unit in common with the first pickface (FIG. 15, Block2020). For example, the first pickface 5, 7 is broken up such that adifferent pickface including individual pickface 5 (or individualpickface 7) is picked by the bot 110 and/or the other first pickface 20,22 is broken up such that a different pickface including individualpickface 20 (or individual pickface 22) is picked by the bot 110. Herethe second pickface is different than the first pickface but includes atleast one of the individual pickfaces of the first pickface so that atleast one case unit is common between the first pickface and the secondpickface. As may be realized, the second pickface may be broken up bythe bot so that a pickface placed on at least one storage shelf with the110 is different than the second pickface and where at least one caseunit is common between the second pickface and the pickface placed onthe at least one storage shelf. As may be realized, for inboundtransfers the pickfaces 5, 7 are transferred from the lifts 150A1, 150A2as a unit, the pickfaces 5, 7 (which may include combined caseunits/totes) at any of the interface stations TS may be distributed whentransported by the bots 110 to the storage array so that one or more ofthe case units/totes in the pickface 5, 7 are transported to differentstorage rack locations (e.g. different storage spaces 130S).

Similarly for outbound transfers (as described in greater detail below)from the storage racks to a load out such as a palletizing cell, ortruck load out, the combined cases/totes of the pickface 5, 7 at any ofthe multiple interfaces stations TS may be distributed in the load out.In one aspect, the distribution of case units/totes at load out iseffected by the lift transferring cases/totes from the combined pickfacein a desired sequence related to the order or sequence of thepredetermined load out. Similarly, each of the multiple loads carried bythe load handling devices LHD may be transferred in a desired sequencerelated to the predetermined load out. For example, in one aspect theload handling device LHD of the lift 150B delivers the multiple loads(e.g. of a common pickface) in ordered sequence at offload in a singleplacing step (where in one aspect the lift 150B picks the case units inthe ordered sequence in one picking step. In other aspects the lift 150Bpicks the case units in multiple picking steps to effect the orderedsequence of case units. In one aspect, at least one pickface in thecombined pickface, that is being carried on a common load handlingdevice, is different (e.g. has a different configuration) than otherpickfaces in the combined pickface.

In one aspect the interface stations TS are configured for a passivetransfer (e.g. handoff) of case units (and/or pickfaces) between the bot110 and the load handing devices LHD of the lifts 150 (e.g. theinterface stations TS have no moving parts for transporting the caseunits) which will be described in greater detail below. For example,also referring to FIG. 3B the interface stations TS and/or bufferstations BS include one or more stacked levels TL1, TL2 of transfer rackshelves RTS (e.g. so as to take advantage of the lifting ability of thebot 110 with respect to the stacked rack shelves RTS) which in oneaspect are substantially similar to the storage shelves described above(e.g. each being formed by rails 1210, 1200 and slats 1210S) such thatbot 110 handoff (e.g. pick and place) occurs in a passive mannersubstantially similar to that between the bot 110 and the storage spaces130S (as described herein) where the case units or totes are transferredto and from the shelves. In one aspect the buffer stations BS on one ormore of the stacked levels TL1, TL2 also serve as a handoff/interfacestation with respect to the load handling device LHD of the lift 150. Inone aspect, where the bots, such as bots 110′, are configured for thetransfer of case units to a single level 130L of storage shelves, theinterface stations TS and/or buffer stations BS also include a singlelevel of transfer rack shelves (which are substantially similar to thestorage rack shelves of the storage levels 130L described above withrespect to, for example, FIG. 1B). As may be realized, operation of thestorage and retrieval system with bots 110′ serving the single levelstorage and transfer shelves is substantially similar to that describedherein. As may also be realized, load handling device LHD handoff (e.g.pick and place) of case units (e.g. individual case units or pickfaces)and totes to the stacked rack shelves RTS (and/or the single level rackshelves) occurs in a passive manner substantially similar to thatbetween the bot 110 and the storage spaces 130S (as described herein)where the case units or totes are transferred to and from the shelves.In other aspects the shelves may include transfer arms (substantiallysimilar to the load handling device transfer arm shown in FIG. 5E,although Z direction movement may be omitted when the transfer arm isincorporated into the interface station TS shelves) for picking andplacing case units or totes from one or more of the bot 110 and loadhandling device LHD of the lift 150. Suitable examples of an interfacestation with an active transfer arm are described in, for example, U.S.patent application Ser. No. 12/757,354 filed on Apr. 9, 2010, thedisclosure of which is incorporated by reference herein in its entirety.

In one aspect, the location of the bot 110 relative to the interfacestations TS occurs in a manner substantially similar to bot locationrelative to the storage spaces 130S. For example, in one aspect,location of the bot 110 relative to the storage spaces 130S and theinterface stations TS occurs in a manner substantially similar to thatdescribed in U.S. patent application Ser. No. 13/327,035 filed on Dec.15, 2011, (now U.S. Pat. No. 9,008,884) and Ser. No. 13/608,877 filed onSep. 10, 2012, (now U.S. Pat. No. 8,954,188), the disclosures of whichare incorporated herein by reference in their entireties. For example,referring to FIGS. 1 and 1B, the bot 110 includes one or more sensors110S that detect the slats 1210S or a locating feature 130F (such as anaperture, reflective surface, RFID tag, etc.) disposed on/in the rail1200. The Slats and/or locating features 130F are arranged so as toidentify a location of the bot 110 within the storage and retrievalsystem, relative to e.g. the storages spaces and/or interface stationsTS. In one aspect the bot 110 includes a controller 110C that, forexample, counts the slats 1210S to at least in part determine a locationof the bot 110 within the storage and retrieval system 100. In otheraspects the location features 130F may be arranged so as to form anabsolute or incremental encoder which when detected by the bot 110provides for a bot 110 location determination within the storage andretrieval system 100.

As may be realized, referring to FIG. 3B, the transfer rack shelves RTSat each interface station TS define multi-load stations (e.g. having oneor more storage case unit holding locations for holding a correspondingnumber of case units or totes) on a common transfer rack shelf RS. Asnoted above, each load of the multi-load station is a single caseunit/tote or a multi-case pickface (e.g. having multiple caseunits/totes that are moved as a single unit) that is picked and paced byeither the bot or load handling device LHD. As may also be realized, thebot location described above allows for the bot 110 to position itselfrelative to the multi-load stations for picking and placing the caseunits/totes and pickfaces from a predetermined one of the holdinglocations of the multi-load station. The interface/handoff stations TSdefine buffers where inbound and/or outbound case units/totes andpickfaces are temporarily stored when being transferred between the bots110 and the load handling devices LHD of the lifts 150.

In one aspect one or more peripheral pickface buffer/handoff stations BS(substantially similar to the interface stations TS and referred toherein as buffer stations BS) are also located at the side of thetransfer deck 130B opposite the picking aisles 130A and rack modules RM,so that the transfer deck 130B is interposed between the picking aislesand each buffer station BS. The peripheral buffer stations BS areinterspersed between or, in one aspect as shown in FIGS. 3A and 3B,otherwise in line with the interface stations TS. In one aspect theperipheral buffer stations BS are formed by rails 1210, 1200 and slats1210S and are a continuation of (but a separate section of) theinterface stations TS (e.g. the interface stations and the peripheralbuffer stations are formed by common rails 1210, 1200). As such, theperipheral buffer stations BS also include one or more stacked levelsTL1, TL2 of transfer rack shelves RTS as described above with respect tothe interface stations TS. The peripheral buffer stations BS definebuffers where case units/totes and/or pickfaces are temporarily storedwhen being transferred from one bot 110 to another different bot 110 onthe same storage level 130L. As maybe realized, in one aspect theperipheral buffer stations are located at any suitable location of thestorage and retrieval system including within the picking aisles 130Aand anywhere along the transfer deck 130B. As may be realized, the caseunit(s) placed at the buffer station BS are, in one aspect, transferredto the interface station TS by a bot 110 or, in other aspects, by anysuitable conveyor that connects the buffer station BS to the interfacestation TS. In one aspect, where the case unit(s) are transferred fromthe buffer station BS to the interface station TS by a bot 110 thattransfer is an opportunistic transfer such that a bot 110 travellingalong the transfer deck, for example, in route for another task (e.g.transferring pickface(s) to storage, sorting pickfaces, transferringpickface(s) from storage, etc.) travelling by the buffer station BSstops to pick the pickface from the buffer station BS and transfer thepickface to the interface station TS while in the process of performingthe other task.

Still referring to FIGS. 3A and 3B in one aspect the interface stationsTS are arranged along the transfer deck 130B in a manner akin to parkingspaces on the side of a road such that the bots 110 “parallel park” at apredetermined interface station TS for transferring case units to andfrom one or more shelves RTS at one or more levels TL1, TL2 of theinterface station TS. In one aspect, a transfer orientation of the bots110 (e.g. when parallel parked) at an interface station TS is the sameorientation as when the bot 110 is travelling along the high speed bottransport path HSTP (e.g. the interface station is substantiallyparallel with a bot travel direction of the transfer deck and/or a sideof the transfer deck on which the lifts 150 are located). Bot 110interface with the peripheral buffer stations BS occurs by parallelparking so that a transfer orientation of the bots 110 (e.g. whenparallel parked) at a peripheral buffer station BS is the sameorientation as when the bot 110 is travelling along the high speed bottransport path HSTP.

In another aspect, referring to FIGS. 4A and 4B, at least the interfacestations TS are located on an extension portion or pier 130BD thatextends from the transfer deck 130B. In one aspect, the pier 130BD issimilar to the picking aisles where the bot 110 travels along rails1200S affixed to horizontal support members 1200 (in a mannersubstantially similar to that described above). In other aspects, thetravel surface of the pier 130BD may be substantially similar to that ofthe transfer deck 130B. Each pier 130BD is located at the side of thetransfer deck 130B, such as a side that is opposite the picking aisles130A and rack modules RM, so that the transfer deck 130B is interposedbetween the picking aisles and each pier 130BD. The pier(s) 130BDextends from the transfer deck at a non-zero angle relative to at leasta portion of the high speed bot transport path HSTP. In other aspectsthe pier(s) 130BD extend from any suitable portion of the transfer deck130B including the ends 130BE1, 130BE2 of the transfer deck 130BD. Asmay be realized, peripheral buffer stations BSD (substantially similarto peripheral buffers stations BS described above) may also be locatedat least along a portion of the pier 130BD.

Referring now to FIGS. 5A, 5B and 5C, as described above, in one aspectthe interface stations TS are passive stations and as such the loadhandling device LHD of the lifts 150A, 150B have active transfer arms orpick heads 4000A, 4000B. In one aspect the lifts 150 communicatingbetween the input and output conveyors 160CA, 160CB and one or more ofthe interface station(s) TS (which in one aspect include stackedtransfer rack shelves RTS) of the stacked deck levels 130C arereciprocating lifts (e.g. the lifts bi-directionally travel in the Zdirection (relative to a reference frame of the lift as shown in FIG.5C) linearly along a single straight line path). The lifts 150 areunconstrained in their rate of travel in the Z direction and are highspeed lifts (rather than a continuous motion or paternoster type lift)where a transfer rate or speed of the lift is not a delimiting factor inthe transfer of case units to and from the storage and retrieval system.For example, a case unit transfer transaction rate of the lifts 150 issubstantially equal to a case unit transfer transaction rate of the bots110. In one aspect the inbound lift modules 150A and the outbound liftmodules 150B have different types of pick heads (as will be describedbelow) while in other aspects the inbound lift modules 150A and theoutbound lift modules 150B have the same type of pick head similar toone of the pick heads described below (e.g. both the lifts 150A, 150Bhave pick head 4000A or both lifts 150A, 150B have pick head 4000B). Forexample, both the inbound and outbound lift modules 150A, 150B have avertical mast 4002 (while one mast is illustrated in other aspects thereare multiple masts). The vertical mast(s) 4002 spans between a baselevel BL (FIG. 3B), such as where, for example, the input and outputconveyors 160CA, 160CB of the input and output stations 1601N, 160UT arelocated, and any desired decks or storage levels 130L of the multi-levelstorage array. One or more carriage(s) or slide(s) 4001 travel along thevertical mast(s) 4002 under the motive force of any suitable drive unit4002D (e.g. connected to, for example, control server 120) configured tolift and lower the slide (and the pick head 4000A, 4000B mountedthereto) between the base level BL and any desired interface stationshelf at a desired storage level 130L. The drive unit 4002D is one ormore of a chain drive, a belt drive, a screw drive, a linear actuator, asolid state drive or any other drive capable of linearly driving theslide(s) and pick heads 4000A, 4000B mounted thereto along the mast(s)4002.

As may be realized, the lifts 150 include any suitable pick headpositioning system for positioning the pick head(s) 4000A, 4000Brelative to the interface station TS shelves. For example, any suitableencoders or position sensors SENS are provided which, along with controlserver 120, provide for position determination of the pick head(s)4000A, 4000B relative to the interface station TS shelves andinput/output conveyors 160CA, 160CB. For example, the control server 120provides control signals to the lift drives 4002D, 4005, 4005A. Thecontrol server 120 also receives signals from the position sensors SENSas the pick head(s) move along the mast 4002 and determines, based onthe signals a location of the pick heads relative to the interfacestation TS shelves. The control server 120 stops the pick head(s) at apredetermined interface station shelf based on the sensor SENS signalsand effects extension of the load handling device LHD as will bedescribed in greater detail below to pick or place one or more caseunit(s) to the interface station TS shelves.

As noted above, the inbound lift module(s) 150A include a pick head4000A that is movably dependent from the mast(s) 4002, such as by beingmounted to the slide(s) 4001 so that as the slide(s) moves the pick head4000A moves with the slide(s) 4001. In this aspect the pick head 4000Aincludes a pick head portion or effector, referred to herein as a loadhandling device LHDA, having one or more tines or fingers 4273 mountedto a base member 4272 so as to form a platform PFM for housing loads.The platform PFM forms a payload support having a common elevationconfigured to hold one or more pickfaces at the common elevation of theplatform PFM. In one aspect the common elevation is a substantially flatcommon surface while in other aspects the common elevation includesstacked shelves or effectors (e.g. where, as illustrated in FIG. 5F, oneor more of the pick heads 4000A, 4000B includes the stacked shelves oreffectors LHDA) with a common pick and place elevation position of thelift so that the lift can pick and place every load at once at onesingle elevation stop of the lift. As may be realized, while the stackedeffectors of the pick head 4000A is illustrated with respect to lift150A it should be understood that the one or more effectors LHDA, LHDBof the pick head 4000B of lift 150B, in one aspect, include stackedeffectors. The fingers 4273 are configured to pass through or otherwisebetween the slats 1210S of the interface stations TS shelves fortransferring one or more case unit(s) between the load handling deviceLHD and the shelves (as will be described in greater detail below). Thebase member 4272 is movably mounted to one or more rail 4360S of frame4200 which in turn is mounted to the slide 4001. Any suitable drive unit4005, such as a belt drive, chain drive, screw drive, gear drive, etc.(which is substantially similar in form but may not be similar incapacity to drive 4002D as the drive 4005 may be smaller than drive4002D) is mounted to the frame 4200 and coupled to the base member 4272for driving the base member 4272 (with the finger(s), i.e. the effectorLHDA) in the direction of arrow 4050 (e.g. the Y direction relative to alift reference frame REFL). The load platform PFM includes one or moreload stations LST1-LST3, each being arranged for holding a caseunit(s)/tote(s) or pickface(s) thereon. In one aspect each platform PFMis illustrated has having three load stations but in other aspects theplatforms have more or less than three load stations. Each of the caseunit(s)/tote or pickface in the one or more load stations LST1-LST3 istransferred to and from the lift 150 as a unit but it should beunderstood that where there are multiple case unit(s)/tote(s) in a loadstation (e.g. a pickface) the pickface, in one aspect is broken up sothat one or more case units that form the pickface are distributed to adifferent section of the storage level 130L than other case unit(s) ofthat pickface while in other aspects the pickface may be placed within astorage space 130S as a unit in the manner described, for example, inU.S. patent application Ser. No. 14/997,892, filed Jan. 15, 2016, andU.S. Provisional Patent Application No. 62/104,513 filed on Jan. 16,2015, the disclosures of which were previously incorporated herein byreference in their entireties.

The outbound lift module(s) 150B also include a pick head 4000B mountedto the slide 4001 so that as the slide moves the pick head 4000B moveswith the slide 4001. In this aspect the pick head 4000B includes one ormore pick head portions or effectors LHDA, LHDB (which are eachsubstantially similar to pick head 4000A) each having one or more tinesor fingers 4273 mounted to a respective base member 4272A. Each basemember 4272A is movably mounted to one or more rail 4360SA of frame4200A which in turn is mounted to the slide 4001. Any suitable driveunit(s) 4005A, such as a belt drive, chain drive, screw drive, geardrive, etc. is mounted to the frame 4200A and coupled to a respectivebase member 4272A for driving the respective base member 4272A (with thefinger(s)) in the direction of arrow 4050 (each effector has arespective drive unit so that each effector is independently movable inthe direction of arrow 4050). While two effectors LHDA, LHDB areillustrated on pick head 4000B the pick head 4000B includes any suitablenumber of effectors that correspond to a number of case unit/pickfaceholding locations of, for example, the interface stations TS so thatcase units/pickfaces are individually picked from the interface stationsTS are described in greater detail below.

In one aspect, referring also to FIG. 5D, one or more of the input andoutput lifts 150 includes multiple pick heads 4000C, 4000D each mountedto a corresponding carriage or slide 4001A, 4001B. Each of the slides4001A, 4001B (and the pick head mounted thereto) is mounted to the mast4002 so as to be independently moveable in the Z direction by arespective drive 4002DA, 4002DB (which is substantially similar to drive4002D described above). While each pick head 4000C, 4000D illustrated inFIG. 5D includes a single load handling device it should be understoodthat one or more of the pick heads, in other aspects, 4000C, 4000Dincludes multiple independently actuated load handling devices in amanner similar to pick head 4000B. As may also be realized, suitableclearance is provided between each of the slides 4001A, 4001B and thepick head(s) mounted thereto so that each pick head is provided with thefull stroke of travel (e.g. from the base level BL to, for example, theinterface station shelves at the top storage level 130L) along the mast4002 is desired.

In another aspect each load handling device, as described above, of thelifts 150A, 150B is configured to sort one or more case units onboardthe load handling device for building pickfaces on the load handlingdevice. For example, referring to FIG. 5E the carriage 4200B includes aframe 4110F having a payload section 4110PL. The payload section 4110PLof the load handling device LHD includes a payload bed 4110PB, a fenceor datum member 4110PF, a transfer arm LHDA and a pusher bar or member4110PR. In one aspect the payload bed 4110PB includes one or morerollers 4110RL that are mounted to the frame 110F so as to besubstantially parallel with the fingers 4273A-4273E where one or morecase units carried within the payload section 110PL can be moved in theX direction (e.g. justified with respect to a predetermined location ofthe frame/payload section and/or a datum reference of one or more caseunits in the lift frame of reference REFL) to position the case unit ata predetermined position within the payload section 4110PL and/orrelative to other case units within the payload section 4110PL (e.g.side to side justification of case units as opposed to fore/aft asdefined by the direction of extension of the transfer arm LHDA asdescribed below, e.g. in the Y direction relative to the lift frame ofreference). In one aspect the rollers 4110RL may be driven (e.g. rotatedabout their respective axes) by any suitable motor for moving the caseunits within the payload section 4110PL. In other aspects the loadhandling device LHD includes one or more side justification movablepusher bar (not shown) for pushing the case units over the rollers4110RL for moving the case unit(s) to the predetermined position withinthe payload section 4110PL along the X direction. The side justificationmovable pusher bar may be substantially similar to that described in,for example, U.S. patent application Ser. No. 13/326,952 filed on Dec.15, 2011, the disclosure of which was previously incorporated byreference herein in its entirety. The pusher bar 4110PR is movable inthe Y direction, relative to the lift reference frame REFL to effect,along with the fence 4110PF and or pick head 4270 of the transfer armLDHA, a fore/aft justification of case unit(s) within the payload area4110PL in the manner described in U.S. Provisional Patent ApplicationNo. 62/107,135 filed on Jan. 23, 2015 previously incorporated herein byreference in their entireties.

Still referring to FIG. 5E, the case units are placed on the payload bed4110PB and removed from the payload bed 4110PB with the transfer armLHDA. The transfer arm LHDA includes a lift mechanism or unit 5000located substantially within the payload section 4110PL as described in,for example, U.S. Provisional Patent Application No. 62/107,135 filed onJan. 23, 2015 previously incorporated herein by reference in theirentireties. The lift mechanism 5000 provides, in addition to or in lieuof movement of the carriage 4200B in the Z direction, both gross andfine positioning of pickfaces carried by the load handling device LHDwhich are to be lifted into position in the storage structure 130 forpicking and/or placing the pickfaces and/or individual case units to andfrom the shelves of the interface stations TS.

The lift mechanism 5000 is configured so that combined axis moves areperformed (e.g. combined substantially simultaneous movement of thepusher bar 4110PR, lift mechanism 5000, pick head extension and fore/aftjustification mechanism(s)), so that different/multi-sku or multi-pickpayloads are handled by the lift 150. In one aspect, the actuation ofthe lifting mechanism 5000 is independent of actuation of the pusher bar4110PR as will be described below. The decoupling of the lift mechanism5000 and pusher bar 4110PR axes provides for combined pick/placesequences effecting a decreased pick/place cycle time, increased storageand retrieval system throughput and/or increased storage density of thestorage and retrieval system as described above. For example, the liftmechanism 5000 provides for lifting case units from the a payload bed4110PL of the load handling device LHD to allow for sorting andjustifying case units to predetermined positions on the payload bed41110PL and thus on the transfer arm LHDA. In one aspect the case unitsare lowered on the payload bed if sorting or justification is desired,otherwise the transfer arm LHDA may remain at least partially lifted toallow the arm to extend and retract for picking/placing case unitsto/from the interface stations TS without a secondary lifting of thetransfer arm LHDA above the fence 4110PF in addition to, for example,traversal of the load handling device LHD along the mast(s) 4002.

The lifting mechanism 5000 may be configured in any suitable manner sothat a pick head 4270 of the load handling device LHD bi-directionally(e.g. reciprocates) moves along the Z axis (e.g. in the Z direction). Inone aspect, the lifting mechanism 5000 includes a mast 5000M and thepick head 4270 is movably mounted to the mast 4200M in any suitablemanner. The mast 4200M is movably mounted to the frame 4110F in anysuitable manner so as to be movable along the Y direction. In one aspectthe frame includes guide rails 4360S to which the mast 4200M is slidablymounted. A transfer arm drive 4005 may be mounted to the frame foreffecting at least movement of the transfer arm LHDA along the Ydirection and the Z direction. In one aspect the transfer arm drive 4005includes an extension motor 4301 and a lift motor 4302. The extensionmotor 4301 may be mounted to the frame 4110F and coupled to the mast4200M in any suitable manner such as by a belt and pulley transmission4260A, a screw drive transmission (not shown) and/or a gear drivetransmission (not shown). The lift motor 4302 may be mounted to the mast4200M and coupled to pick head 4270 by any suitable transmission, suchas by a belt and pulley transmission 4271, a screw drive transmission(not shown) and/or a gear drive transmission (not shown). As an example,the mast 4200M includes guides, such as guide rails 4280, along whichthe pick head 4270 is mounted for guided movement in the Z directionalong the guide rails 4280. In other aspects the pick head 4270 ismounted to the mast in any suitable manner for guided movement in the Zdirection. With respect to the transmissions In other aspects anysuitable linear actuators are used to move the pick head in the Zdirection. The transmission 260A for the extension motor 301 issubstantially similar to that described herein with respect totransmission 271.

Still referring to FIG. 5E the pick head 4270 of the load handlingdevice LHD transfers case units between the load handling device LHD andinterface stations TS (see e.g. FIG. 3A) and in other aspectssubstantially directly between the bot 110 and a lift module(s) 150. Inone aspect, the pick head 4270 includes a base member 4200B1, one ormore tines or fingers 4273A-4273E and one or more actuators 4274A,4274B. The base member 4200B1 is mounted to the mast 4200M, as describedabove, so as to ride along the guide rails 4280. The one or more tines4273A-4273E are mounted to the base member 4200B1 at a proximate end ofthe tines 4273A-4273E so that a distal end of the tines 4273A-4273E(e.g. a free end) is cantilevered from the base member 4200B1. Referringagain to FIG. 1A, the tines 4273A-4273E are configured for insertionbetween slats 1210S that form the case unit support plane CUSP of theinterface station TS shelves.

One or more of the tines 4273A-4273E is movably mounted to the basemember 4200B1 (such as on a slide/guide rail similar to that describedabove) so as to be movable in the Z direction. In one aspect any numberof tines are mounted to the base member 4200B1 while in the aspectillustrated in the figures there are, for example, five tines4273A-4273E mounted to the base member 4200B1. Any number of the tines4273A-4273E are movably mounted to the base member 4200B1 while in theaspect illustrated in the figures, for example, the outermost (withrespect to a centerline CL of the pick head 4270) tines 4273A, 4273E aremovably mounted to the base member 4200B1 while the remaining tines4273B-4273D are immovable relative to the base member 4200B1.

In this aspect the pick head 4270 employs as few as three tines4273B-4273D to transfer smaller sized case units (and/or groups of caseunits) to and from the load handling device LHD and as many as fivetines 4273A-4273E to transfer larger sized case units (and/or groups ofcase units) to and from the load handling device LHD. In other aspects,less than three tines are employed (e.g. such as where more than twotines are movably mounted to the base member 4200B1) to transfer smallersized case units. For example, in one aspect all but one tine4273A-4273E is movably mounted to the base member 4200B1 so that thesmallest case unit being transferred to and from the load handlingdevice without disturbing other case units on, for example, the shelvesof the interface stations has a width of about the distance X1 betweenslats 12105 (see FIG. 1A).

The immovable tines 4273B-4273D define a picking plane SP of the pickhead 4270 and are used when transferring all sizes of case units (and/orpickfaces) while the movable tines 4273A, 4273E are selectively raisedand lowered (e.g. in the Z direction with the actuators 274A, 274B)relative to the immovable tines 4273B-4273D to transfer larger caseunits (and/or pickfaces). Still referring to FIG. 5E an example is shownwhere all of the tines 4273A-4273E are positioned so that a case unitsupport surface SF of each tine 4273A-4273E is coincident with thepicking plane SP of the pick head 4270 however, as may be realized, thetwo end tines 4273A, 4273E are movable so as to be positioned lower(e.g. in the Z direction) relative to the other tines 4273B-4273D sothat the case unit support surface SF of tines 4273A, 4273E is offsetfrom (e.g. below) the picking plane SP so that the tines 4273A, 4273E donot contact the one or more case units carried by the pick head 4270 anddo not interfere with any unpicked case units positioned inpredetermined case unit holding locations on the interface station TSshelves.

The movement of the tines 4273A-4273E in the Z direction is effected bythe one or more actuators 4274A, 4274B mounted at any suitable locationof the transfer arm LHDA. In one aspect, the one or more actuators4274A, 4274B are mounted to the base member 4200B1 of the pick head4270. The one or more actuators are any suitable actuators, such aslinear actuators, capable of moving one or more tines 4273A-4273E in theZ direction. In the aspect illustrated in, for example, FIG. 5E there isone actuator 4274A, 4274B for each of the movable tines 4273A, 4273E sothat each moveable tine is independently movable in the Z direction. Inother aspects one actuator may be coupled to more than one movable tineso that the more than one movable tine move as a unit in the Zdirection.

As may be realized, movably mounting one or more tines 4273A-4273E onthe base member 4200B1 of the pick head 4270 provides for full supportof large case units and/or pickfaces on the pick head 4270 while alsoproviding the ability to pick and place small case units withoutinterfering with other case units positioned on, for example, theshelves of interface stations TS. The ability to pick and place variablysized case units without interfering with other case units at theinterface stations reduces a size of a gap G (FIG. 6) between case unitson the interface stations shelves

Referring again to FIG. 5E, it is again noted that the pusher bar 4110PRis movable independent of the transfer arm LHDA. The pusher bar 4110PRis movably mounted to the frame 4110F in any suitable manner such as by,for example, a guide rod and slide arrangement and is actuated along theY direction (e.g. in a direction substantially parallel to theextension/retraction direction of the transfer arm LHDA). In one aspectat least one guide rod 4360 is mounted within the payload section 4110PLfor guiding movement of the pusher 4110PR in the Y direction. In oneaspect, at least the guide rod/slide arrangement holds the pusher bar4110PR captive within the payload section 4110PL. The pusher bar 4110PRis actuated by any suitable motor and transmission, such as by motor4303 and transmission 4303T. In one aspect the motor 4303 is a rotarymotor and the transmission 4303T is a belt and pulley transmission. Inother aspects the pusher bar 110PR may be actuated by a linear actuatorhaving substantially no rotary components.

The pusher bar 4110PR is arranged within the payload section 4110PL soas to be substantially perpendicular to the rollers 4110RL and so thatthe pusher bar 4110PR does not interfere with the pick head 4270 (thepusher bar 4110PR includes slots 4351 into which the fingers 4273A-4273Epass when lowered into the payload bed 4110PB where the slots 4351 aresized to allow unhindered movement of the pusher bar relative to thefingers 4273A-4273E). The pusher bar 4110PR also includes one or moreapertures through which the rollers 4110RL pass where the apertures aresized to allow free rotation of the rollers about their respective axes.As may be realized, the independently operable pusher bar 4110PR doesnot interfere with the rollers 4110PR, extension of the transfer armLHDA in the transverse direction (e.g. Y direction) and thelifting/lowering of the pick head 4270.

As may be realized, the lift modules 150A, 150B are under the control ofany suitable controller, such as control server 120, such that whenpicking and placing case unit(s) the pick head is raised and/or loweredto a predetermined height corresponding to a shelf of an interfacestation TS at a predetermined storage level 130L. At the interfacestations TS the pick head 4000A, 4000B, 4270 or individual portionthereof (e.g. effector LHDA, LHDB), corresponding to one or more caseunit holding location(s) of the interface station TS from which one ormore case unit(s) are being picked, is extended so that the fingers 4273are interdigitated between the slats 1210S (as illustrated in FIG. 5B)underneath the case unit(s) being picked. The lift 150A, 150B raises thepick head 4000A, 4000B, 4270 to lift the case unit(s) from the slats1210S and retracts the pick head 4000A, 4000B, 4270 for transport of thecase unit(s) to another level of the storage and retrieval system, suchas for transporting the case unit(s) to output station 160UT. Similarly,to place one or more case unit(s) the pick head 4000A, 4000B, 4270 orindividual portion thereof (e.g. effector LHDA, LHDB), corresponding toone or more case unit holding location(s) of the interface station TSfrom which one or more case unit(s) are being placed, is extended sothat the fingers 4273 are above the slats. The lift 150A, 150B lowersthe pick head 4000A, 4000B, 4270 to place the case unit(s) on the slats1210S and so that the fingers 4273 are interdigitated between the slats1210S underneath the case unit(s) being picked.

An example of a lift 150 case unit(s) transfer transaction including acase unit(s) multi-pick and place operation and on the fly sortation ofthe case units for creating a mixed pallet load MPL (as shown in FIG. 2)according to a predetermined order out sequence and/or in thepredetermined order sequence (e.g. an order out sequence) of pickeditems according to, for example, an order, fulfilling one or morecustomer orders, in which case units CU are placed in one or morebag(s), tote(s) or other container(s) TOT at an operator station 160EP(as shown in FIG. 16) as will be described with respect to FIGS. 5A-5E,6 and 7-7E in accordance with an aspects of the disclosed embodiment.For example, referring to FIG. 6 a customer order may require caseunit(s) 7 and 5 to be delivered to output conveyor 160CB such that caseunits are carried and transferred by a common load handling device LHDof lift 150B1 from different holding locations of one or more interfacestation shelves 7000A-7000F in a single pass of the stack of interfacestations TS. To efficiently use each lift 150 in the storage andretrieval system 100 the controller, such as control server 120,determines on which interface stations(s) case units 5, 7 are located.The controller sends commands to a lift, such as lift 150B1 associatedwith the interface stations TS where case units 5, 7 are located to pickone or more of the outbound case units. As described herein, in oneaspect, the lifts 150 may move cases from the interface stations TS atthe different storage levels to the interface station of the outboundconveyors. In other aspects, the lifts 150 may move case units betweenstorage levels such as from shelf 7000A to shelf 7000D where the caseunits transferred from shelf 7000A may be picked from shelf 7000D (e.g.combined with case units previously disposed on shelf 7000D) by the lift150 for transfer to the interface station of the outbound conveyor. Inone aspect, the control server 120 is configured to command the lift150, and effect with the lift 150 outbound flow (which may also bereferred to as order fulfillment stream(s), outbound stream(s) or orderfulfillment) sortation of case order(s) independent of the pick order ofcases from the storage area by the bot 110 forming a pickface. This maybe referred to for description purposes as outbound flow sortation withthe lift 150 at transfer stations (and/or at buffer stations).

In one aspect where the lift 150B1 picks case units 5, 7 from a commonshelf 7000B of an interface station TS the lift 150B1 moves one or moreload handling devices LHD, LHD1, LHD2 of the lift (and the pick head4000A, 4000B, 4000C, 4000D, 4270 thereon) in the Z direction so that thetransfer arm LHDA, LHDB is located substantially at a level of theinterface station shelf 7000B (FIG. 8, Block 11000). The transfer armLHDA, LHDB of the one or more load handling devices LHD, LHD1, LHD2 isextended (e.g. extension of a common transfer arm as in FIG. 5A or thesubstantially simultaneous extension of two transfer arms as in FIG. 5Cand 5D) in the Y direction so that the fingers 4273 are disposed betweenthe slats 1210S below the case units 5, 7 (FIG. 8, Block 11010). Thelift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2in the Z direction so that the fingers 4273 pass through the slats 1210Sto lift/pick the case units 5, 7 from the interface station shelf 7000B(FIG. 8, Block 11020). The transfer arm LHDA, LHDB is retracted in the Ydirection so as to place the case units 5, 7 within a transfer column TC(e.g. an area of open space in which the load handling device travelsalong the Z direction free from interference from the interface stationsand outbound conveyors) of the lift 150B1 (FIG. 8, Block 11030). Thelift 150B1 moves the one or more load handling devices LHD, LHD1, LHD2in the Z direction so that the transfer arm LHDA, LHDB is locatedsubstantially at a level of an interface station 160TS of the conveyor160CB (FIG. 8, Block 11040). The transfer arm LHDA, LHDB of the one ormore load handling devices LHD, LHD1, LHD2 is extended in the Ydirection so as to place the case units 5, 7 substantially above theinterface station 160TS (FIG. 8, Block 11050) and the lift 150B1 movesthe one or more load handling devices LHD, LHD1, LHD2 in the Z directionso that the fingers 4273 pass through the slats of the interface station160TS (in a manner similar to that illustrated in FIG. 5B) tolower/place the case units 5, 7 on a shelf of the interface station160TS (FIG. 8, Block 11060). The transfer arm LHDA, LHDB is retracted inthe Y direction so as to place the transfer arm LHDA, LHDB within thetransfer column TC of the lift 150B1 (FIG. 8, Block 11070). Here caseunits carried at all load stations LST1-LST3 (e.g. case unit holdinglocations) of a common platform PFM (e.g. as in FIG. 5A and as in FIGS.5C, 5D where the simultaneous extension/retraction of transfer armsLHDA, LHDB effects a common platform) are picked, transferred and placedin unison.

In one aspect, a multiple transfer arm load handling device LHD as inFIG. 5C (and also the individually operable load handling devices LHD1,LHD2 of FIG. 5D) picks and places case units from more than oneinterface station TS at different storage levels 130LA, 130LB andtransfers the case units to the same or different outbound conveyortransfer stations TS (e.g. such as when the transfer stations TS of oneor more the outbound conveyors serving a common lift 150 are stacked oneabove the other). For exemplary purposes only, a customer order mayrequire case units 7, 9 to be delivered to conveyor 160CB. Again, toefficiently use each lift 150 in the storage and retrieval system 100the controller, such as control server 120, determines on whichinterface stations(s) case units 7, 9 are located. The controller sendscommands to a lift, such as lift 150B1 associated with the interfacestations TS where case units 7, 9 are located to pick one or more of theoutbound case units in a single pass of the load handling device LHD.Here, case units 7, 9 are located on different shelves 7000A-7000F ofdifferent interface stations TS such that the lift 150B1 moves one ormore load handling devices LHD, LHD1, LHD2 of the lift (and the pickhead 4000A, 4000B, 4000C, 4000D, 4270 thereon) in the Z direction sothat the transfer arm LHDA, LHDB is located substantially at a level130LA, 130LC of one of the interface station shelves 7000A, 7000B shelf(FIG. 9, Block 12000). The transfer arm LHDA, LHDB of the one or moreload handling devices LHD, LHD1, LHD2 is extended in the Y direction sothat the fingers 4273 are disposed between the slats 1210S below one ofthe case units 7, 9 (FIG. 9, Block 12010) such as case unit 7 when caseunit 7 is being picked on an upstroke of the lift 150B before pickingcase unit 9 or case unit 9 when case unit 9 is being picked on a downstroke of the lift 150B before picking case unit 7. The lift 150B1 movesthe one or more load handling devices LHD, LHD1, LHD2 in the Z directionso that the fingers 4273 pass through the slats 1210S to lift/pick oneof the case units 7, 9 (which is some aspects may be a pickfaceincluding more than one case unit) from the interface station shelf7000B (FIG. 9, Block 12020). The transfer arm LHDA, LHDB is retracted inthe Y direction so as to place the case units 7, 9 within a transfercolumn TC (e.g. an area of open space in which the load handling devicetravels along the Z direction free from interference from the interfacestations and outbound conveyors) of the lift 150B1 (FIG. 9, Block12030). The lift 150B1 moves the one or more load handling devices LHD,LHD1, LHD2 in the Z direction so that the transfer arm LHDA, LHDB islocated substantially at a level of interface station shelf 7000A, 7000Bwhere the other case unit 7, 9 is located (FIG. 9, Block 12035) forpicking the other case unit in the manner described above (FIG. 9,Blocks 12010, 12020, 12030). The lift 150B1 moves the one or more loadhandling devices LHD, LHD1, LHD2 in the Z direction so that the transferarm LHDA, LHDB is located substantially at a level of an interfacestation 160TS of the conveyor 160CB (FIG. 9, Block 12035). The transferarm LHDA, LHDB of the one or more load handling devices LHD, LHD1, LHD2is extended in the Y direction so as to place the case units 7, 9substantially above the interface station 160TS (FIG. 9, Block 12050)and the lift 150B1 moves the one or more load handling devices LHD,LHD1, LHD2 in the Z direction so that the fingers 4273 pass through theslats of the interface station 160TS (in a manner similar to thatillustrated in FIG. 5B) to lower/place the case units 7, 9 on a shelf ofthe interface station 160TS (FIG. 9, Block 12060). In one aspect thecase units 7, 9 are placed on the interface station 160TS substantiallysimultaneously as a unit while in other aspects the case units 7, 9 areplaced on the interface station 160TS sequentially at different times,such as one after another and/or placed to different outbound conveyorsinterface stations 160TS (e.g. such as when the transfer stations TS ofone or more the outbound conveyors serving a common lift 150 are stackedone above the other) according to a predetermined order out sequence forbuilding the mixed pallet MPL (FIG. 2). The transfer arm LHDA, LHDB isretracted in the Y direction so as to place the transfer arm LHDA, LHDBwithin the transfer column TC of the lift 150B1 (FIG. 9, Block 12070).

In one aspect a common load handling device LHD, LHD1, LHD2 isconfigured to pick/place one or more case units from multiple interfacestation TS shelves with a common transfer arm where the case units aresorted on the fly (e.g. during transport on the lift) and/or justifiedon the load handling device LHD, LHD1, LHD2. For example, the outboundcase units 5, 7 are located on interface station shelves 7000B, 7000B ofdifferent storage levels 130LA, 130LB. Again, to efficiently use eachlift 150 in the storage and retrieval system 100 the controller, such ascontrol server 120, determines on which interface stations(s) case units5, 7 are located. The controller sends commands to a lift, such as lift150B1 associated with the interface stations TS where case units 5, 7are located to pick one or more of the outbound case units in a singlepass of the load handling device LHD. Here For example, referring toFIGS. 6, 7 and 7A-7E the load handling device LHD, LHD1, LHD2 of lift150B1 picks case unit 7 (which may be a pickface of more than one caseunit) from interface station shelf 7000B in the manner described above(FIG. 10, Block 13000). The case unit(s) 7 is justified on the loadhandling device towards the rear of the payload section 4110PL as willbe described in greater detail below (FIG. 10, Block 13005). The loadhandling device LHD, LHD1, LHD2 continues to travel along the mast 4002in a common pass of the vertical stack of interface stations TS andpicks case unit 5 from a different interface station shelf 7000D withthe common transfer arm LHDA so that both case unit(s) 7, 5 are locatedadjacent one another on the common transfer arm LHDA (FIG. 10, Block13010). As may be realized, in one aspect, the controller 120 isconfigured to effect picking of the case unit(s) 5, 7 in any suitableorder such as, for example, an order that is opposite an order in whichthe case unit(s) are placed at the interface station 160TS of theconveyor 160CB according to the predetermined order out sequence forforming the mixed pallet MPL.

Here the load handling device LHD, LHD1, LHD2 grips both case units 7, 5within the payload section 4110PL in the manner described below (FIG.10, Block 13020). The load handling device LHD, LHD1, LHD2 travels alongthe mast 4002 and interfaces with one or more output lifts 150B1 (FIG.10, Block 13030). The load handling device LHD, 1HD1, LHD2 separates thecase units 7, 5 within the payload section 4110PL, as will be describedin greater detail below, so that case unit(s) are separated in anysuitable manner such as, for example, so that case unit(s) 5 isjustified towards the front of the payload section 4110PL and caseunit(s) 7 is justified towards the back of the payload section 4110PL(FIG. 10, Block 13040). At least the case unit 5 is transferred to theinterface station 160TS (FIG. 10, Block 13050). The load handling deviceLHAD, LHD1, LHD2 retracts the transfer arm LHDA, LHDB to return thenon-transferred case unit(s) 7 (e.g. case units retained within thepayload section) to the payload section 4110PL (FIG. 10, Block 13060)and grips the case unit 7 (FIG. 10, Block 13020). The case unit(s) 7 istransported to another interface station 160TSA of output lift 150B1 (orplaced at the same interface station 160TS sequentially after placementof case unit(s) 5 at interface station 160TS) (FIG. 10, Block 13030),justified toward the front of the payload section 4110PL (FIG. 10, Block13040), and transferred to interface station 160TS, 160TSA, as describedabove (FIG. 10, Block 13050). In other aspects, depending on thepredetermined case unit output sequence, the load handling device LHD,LHD1, LHD2 places both case unit(s) 7, 5 at a common location/position,such as simultaneously at a single interface station of lifts 150B1.

As noted above, because the pusher bar 4110PR is a separate, standaloneaxis of the load handling device LHD, LHD1, LHD2 that operates free ofinterference from the pick head 4270 extension and lift axes, the pusherbar 4110PR can be operated substantially simultaneously with the liftingand/or extension of the transfer arm LHDA, LHDB. The combined axis moves(e.g. the simultaneous movement of the pusher bar 4110PR with thetransfer arm LHDA, LHDB extension and/or lift axes) provides forincreased payload handling throughput and effects the ordered (e.g.according to the predetermined load out sequence) multi-pick of two ormore case units from one or more interface station shelves 7000A-7000F,in one common pass of the vertical stack of interface stations TS. Forexample, referring again to FIGS. 7-7E during a transfer arm LHDA, LHDBmulti-pick/place sequence the pusher bar 4110PR is prepositioned (as thecase unit(s) and/or pickface are being picked and transferred into thepayload section 4110PL) to a location that is a predetermined distanceX2 away from the contact depth X3 (e.g. the depth of the tines occupiedby the case unit(s) and/or pickface 7 when being picked/placed frominterface station shelf 7000D or other case unit holding location) (FIG.11, Block 1100). The distance X2 is a minimized distance that onlyallows sufficient clearance between pusher bar 110PR and the caseunit(s) to allow the case unit(s) to be seated on the rollers 4110RL. Asthe case unit(s) 7 are lowered onto the rollers 4110RL (FIG. 11, Block1110) the distance travelled by the pusher bar 4110PR to contact thecase unit(s) 7 is a shorter distance X2 when compared to moving from aback side 4402 (relative to the Y direction and an access side 4401 ofthe payload section 4110PL) of the payload section 4110PL a distance X4as with conventional transport vehicles. When the case unit(s) 7 arelowered by the transfer arm LHDA, LHDB and transferred to the rollers4110RL so as to be solely supported by the rollers 4110RL, the pusherbar 4110PR is actuated to forward (relative to the lateral direction andan access side 4401 of the payload section 110PL) justify the caseunit(s) 7 (FIG. 11, Block 1120). For example, the pusher bar 4110PB maypush the case unit(s) 7 in the Y direction so that the case unit(s)contact the fence 4110PF (which is located at the access side 4401 ofthe payload section 4110PL) so that a case unit reference datum may beformed through contact between the case unit(s) 7 and the fence 4110PF.In one aspect the pusher bar 4110PR may engage or otherwise grip thecase unit(s) 7 during transport of the case units (e.g. so as to holdthe case unit(s) against the fence 4110PF) for maintaining the caseunit(s) 7 in a predetermined spatial relationship with each other andthe reference frame REFL (FIG. 5E) of the load handling device LHD,LHD1, LHD2 (FIG. 11, Block 1130). When placing the case unit(s) thepusher bar 4110PR, after justifying the case unit(s) 7 against the fence4110PF, is withdrawn (e.g. in the Y direction) from contact with thecase unit(s) 7 (FIG. 11, Block 1140). Substantially immediately afterthe pusher bar 4110PR disengages the case unit(s) 7 one or more of thelift axis (e.g. in the Z direction) and extension axis (e.g. in the Ydirection) of the transfer arm LHDA, LHDB are actuated substantiallysimultaneously with the withdrawing movement of the pusher bar 4110PR(FIG. 11, Block 1150). In one aspect both the lift and extension axesare actuated when the pusher bar is withdrawn from contact with the caseunit(s) 7 while in other aspect one of the lift and extension axes isactuated. As may be realized, the simultaneous movement of the transferarm 4110PA lift axis and/or extension axis with the withdrawal of thepusher bar 4110PR as well as the decreased distance the pusher moves tojustify the case unit(s) 7 decreases the time needed to transfer caseunit(s) 7 (e.g. that are sorted on the load handling device LHD, LHD1,LHD2) to and from the load handling device and increases throughput ofthe storage and retrieval system 100.

In another aspect of the disclosed embodiment, as may be realized, inthe multi-pick/place sequence multiple case units are substantiallysimultaneously carried and manipulated within the payload section 4110PLto further increase throughput of the storage and retrieval system 100and to effect the multi-pick/place sequence in accordance with apredetermined order out sequence for an outbound flow of case units.Referring also to FIG. 1, the lift 150B receives pick and place commandsfrom, for example, control server 120 (and/or warehouse managementsystem 2500) and executes those commands (e.g. under the control ofcontrol server 120 (or a lift controller) for forming the orderedmulti-pick. Here the lift moves the load handling device LHD, LHD1, LHD2in the Z-direction to pick two or more case units according to thepredetermined order out sequence (FIG. 12, Block 1201A). In one aspectthe manipulation of the case units 7, 5 is a sorting of the case units(in other words picking and placing of case units according to thepredetermined load out sequence) where the cases are positioned on thetransfer arm LHDA, LHDB for picking/placement of the case units and/orpositioned so that the case units are not transferred and remain on thetransfer arm LHDA, LHDB while other case units are transferred to andfrom the transfer arm LHDA, LHDB. Here, the load handling device LHD,LHD1, LHD2 travels in the Z direction and stops at a predetermined shelf7000A-7000F of an interface station TS, according to the predeterminedorder out sequence, where the load handling device LHD, LHD1, LHD2 picksone or more case units from the predetermined shelf 7000A-700F of theinterface station TS with a common transfer arm LHDA, LHDB whereplacement of the case units on the common transfer arm LHDA, LHDBcorresponds to the predetermined order out sequence as will be describedin greater detail below (e.g. the case units are sorted on-the-fly, e.g.during a single or unidirectional pass/traversal of the lift 150,without reversing direction or in one stroke, relative to the interfacestations, noting that vertical movement of the lift 150 is notnecessarily continuous vertical movement).

As an example of case manipulation on the bot 110, still referring toFIGS. 5E, 7, 7A-7E, case unit(s) 7 may be picked from a case unitholding location (e.g. such as interface station shelf 7000D foreffecting the ordered multi-pick (FIG. 12, Block 1201B). As the caseunit(s) 7 is being transferred into the payload section 4110PL thepusher bar 4110PR may be pre-positioned (FIG. 12, Block 1204) adjacentthe fence 4110PF so that the pusher bar 4110PR is positioned between thecase unit(s) 7 and the fence 4110PF when the case unit(s) 7 is loweredfor transfer to the rollers 4110RL (FIG. 12, Block 1205). The pusher bar4110PR is actuated to push the case unit(s) 7 (resting on the rollers4110RL) in the Y direction towards the back (e.g. rear) 4402 of thepayload section 4110PL so that the case unit(s) 7 contacts ajustification surface 4273JS (FIG. 10) of the tines 4273A-4273E and isjustified to the back 4402 of the payload section 4110PL (FIG. 12, Block1210).

In one aspect, the load handling device LHD, LHDA, LHD2 continues totraverse mast 4002 in the same direction (e.g. so that all of the caseunits in the ordered multi-pick are picked in the common pass of thevertical stack of interface stations TS with the load handling deviceLHD, LHD1, LHD2 travelling in a single direction) and stops at anotherdifferent predetermined shelf 7000A-7000F of a different interfacestation TS according to the predetermined order out sequence. As notedabove, the pusher bar 4110PR remains in contact with (e.g. grips) thecase unit(s) 7 during transport of the case unit(s) between interfacestation shelves 7000A-7000F so that the case unit(s) 7 remains in apredetermined location at the back 4402 of the payload section 4110PL(and/or at a predetermined location in the X direction) relative to thereference frame REFL of the lift 150B1 (FIG. 12, Block 1215). To picksubsequent case units, from for example, the another interface stationshelf 7000B the pusher bar 4110PR is moved in the Y direction todisengage the case unit(s) 7 and the lift and extension axes of thetransfer arm LHDA, LHDB are actuated to retrieve another case unit(s) 5from the other interface station shelf 7000B (FIG. 12, Block 1220).While the case unit(s) 5 are being picked the pusher bar 4110PR ispositioned in the Y direction adjacent the back 4402 of the payloadsection 4110PL so as to be located between the case units 7 and thejustification surface 4273JS of the tines 4273A-4273E (FIG. 12, Block1225). The case unit(s) 5 are transferred into the payload section andlowered/placed on the rollers 4110RL (FIG. 12, Block 1230) so that thecase units 7, 5 are arranged relative to each other along the Y axis.The pusher bar 4110PR is actuated in the Y direction to push the caseunits 7, 5 towards the fence 4110PF to forward justify the case units 7,5 (FIG. 12, Block 1234) and grip/hold the case units 7, 5 for transport(FIG. 12, Block 1235). As may be realized, in one aspect the case units7, 5 are placed at the interface station 160TS together as a unit whilein other aspects the case units 7, 5 are sorted, e.g. transported to andplaced at different interface stations 160TS, 160TSA (FIG. 12, Block1240).

Where the case units 7, 5 are sorted (FIG. 12, Block 1250) for placementat a common interface station 160TS, 160TSA (such as for sequential butchronologically spaced apart, placement of case unit) or at differentinterface stations 160TS, 160TSA, the case units 7, 5 are separated fromeach other in the payload section 4110PL. For example, the pick head4270 of the transfer arm LHDA, LHDB may be moved in the Z direction tolift the case units 7, 5 from the rollers 4110RL by an amount sufficientto allow the pusher bar 4110PR to pass beneath the case unit(s) (FIG.13, Block 1250A). As the case units 7, 5 are lifted the pusher bar4110PR is positioned along the Y direction so as to be located betweenthe case units 7, 5 (see FIG. 7E) (FIG. 13, Block 1250B). The pick head4270 is lowered so that the case units 7, 5 are transferred to therollers 4110RL and so that the pusher bar is inserted between the caseunits 7, 5 (FIG. 13, Block 1250C). The pusher bar 4110PR is moved in theY direction (e.g. to separate the case unit(s)) to move case unit(s) 7towards the back 402 of the payload section 4110PL (e.g. against thejustification surface 4273JS of the tines 4273A-4273E or any othersuitable position) while the case unit(s) 5 remain at the front of thepayload section 4110PL adjacent the fence 4110PF (e.g. as shown in FIG.7C) (FIG. 13, Block 1250D). As may be realized, where the case units areheld against the justification surface 4273JS of the tines duringtransport, the pusher bar is moved in the Y direction (e.g. to separatethe case unit(s)) to move case unit(s) 5 towards the front 4401 of thepayload section 4110PL (e.g. against the fence 4110PF or any othersuitable position) while the case unit(s) 7 remain at the back of thepayload section 4110PL adjacent the justification surface 4273JS. Thepusher bar 4110PR may also be moved in the Y direction to re-justify thecase unit(s) 5 against the fence 4110PF to position the case unit(s) onthe tines 4273A-4273E for placement at the interface station 160TS,160TSA (FIG. 13, Block 1250E). As may be realized, with the case unit(s)7 being positioned substantially against the justification surface4273JS of the tines 4273A-4273E (e.g. of the pick head 4270) the caseunit(s) 5 can be placed at the interface station 160TS, 160TSAsubstantially without interference from the case unit(s) 7 (FIG. 13,Block 1250F), e.g. the case unit 7 is free from contacting case unitsdisposed at the case unit holding location. The case unit(s) 7 islowered/transferred back into the payload section 4110PL (e.g. byretracting and lowering the transfer arm 4110PA) (FIG. 13, Block 1250G).The pusher bar 4110PR, which is pre-positioned between the justificationsurface 4273JS and the case unit(s) 7, pushes the case unit(s) 7, whichis disposed on the rollers 4110RL, against the fence 4110PF to forwardjustify the case unit(s) 7 for placement at the same or anotherinterface station 160TS, 160TSA (e.g. different than the holdinglocation that case unit (s) 5 were placed) (FIG. 13, Block 1250H). Thepusher bar 4110PR remains against the case unit(s) 7 for gripping (e.g.with the fence) the case unit(s) during transport to the other interfacestation 160TS, 160TSA (FIG. 13, Block 12501). The pusher bar 4110PRmoves away from the case unit(s) 7 and the transfer arm is actuated tolift and extend the pick head 4270 for placing the case unit(s) 7 at theother interface station 160TS, 160TSA (FIG. 13, Block 1250J).

In one aspect, referring again to FIG. 5D, a lift with multipleindividually operable load handling devices LHD1, LHD2 picks and placescase units from more than one interface station TS at different storagelevels 130LA, 130LB and transfers the case units to the same ordifferent outbound conveyor interface stations TS (e.g. such as when thetransfer stations TS of one or more the outbound conveyors serving acommon lift 150 are stacked one above the other). Here, each of theindividually operable load handling devices LHD1, LHD2 picks and placescase units from the interface station shelves 7000A-7000F and deliversthe picked case units to the outbound conveyor 160CB in a mannersubstantially similar to the manner described above with respect toFIGS. 8, 9 and 10. It is noted that in one aspect each load handlingdevice LHD1, LHD2 includes a single transfer arm LHDA, LHDB (see FIGS.5A, 5D) or more than one transfer arm LHDA, LHDB (see FIG. 5C) (e.g. oneload handling device include a single transfer arm while the other loadhandling device includes more than one transfer arm; both load handlingdevices include a single transfer arm; both load handling devicesinclude more than one transfer arm). The load handling devices LHD1,LHD2 in one aspect include the sorting and justification mechanismsdescribed above with respect to FIG. 5E.

The output lifts 150B1, 150B2 transfer the ordered multi-pick(s) placedon the shelves 7000A-7000L by the bots 110 to the output station 16OUTalso in accordance with the predetermined order out sequence. Forexample, referring again to FIG. 6, the pickfaces 1-22 are picked by thelifts 150B1, 150B2 in sequenced order so that the pickfaces 1-22 aredelivered to the output station 160UTin the predetermined order(indicated by, for example, the number associated with each caseunit/pickface illustrated in FIG. 6) needed to form the mixed palletload MPL (FIG. 2) and/or in the predetermined order sequence (e.g. anorder out sequence) of picked items according to, for example, an order,fulfilling one or more customer orders, in which case units CU aresequenced for placement in one or more bag(s), tote(s) or othercontainer(s) TOT at an operator station 160EP. As such, each of theinterface stations TS of each lift 150B1, 150B2 forms a buffer thatholds one or more case unit(s) until the case unit(s) are needed andpicked by the respective lift 150B1, 150B2 for forming the mixed palletload.

Referring to FIG. 17, in accordance with aspects of the disclosedembodiment, storage spaces arrayed on racks along picking aisles areprovided (FIG. 17, Block 1600). Multiple level decks are also provided(FIG. 17, Block 1610), where at least one deck level of the multiplelevel decks communicates with each aisle, where the multiple level decksand aisles define a rolling surface for an autonomous transport vehicleat each level of the multiple level decks. Racks at multiple rack levelsare accessed from a respective rolling surface that is common to themultiple rack levels (FIG. 17, Block 1620), where the racks are disposedalong at least one aisle at each level of the multiple level decks. Inone aspect, a vertical pitch between rack levels varies for a portion ofa respective aisle. In one aspect, the vertical pitch between at leasttwo rack levels of the portion of the respective aisle is related toanother vertical pitch between at least two other rack levels of anotheraisle portion of the respective aisle so that the autonomous transportvehicle effects multiple picks in an ordered sequence in a common aislepass. In one aspect, the vertical pitch between at least two rack levelsof the portion of the respective aisle is related to another verticalpitch between at least two other rack levels of another aisle portion ofthe respective aisle so that the vertical pitch and the other verticalpitch effects substantially filling a vertical space between themultiple deck levels with stored items.

As may be realized, the load handling devices described above areconfigured to hold one or more pickfaces of differing sizes and/orincluding any number of case units. For exemplary purposes only, FIG. 5Gillustrates a load handing device LHDA holding two pickfaces PCKFC1,PCKFC2. It is noted that load handling device LHDA is shown forillustration purposes only and it should be understood that any of theload handling devices described herein are configured in a mannersubstantially similar to that described with respect to load handlingdevice LHDA. Here pickface PCKFC1 includes a single case unit CU1 whilepickface PCKFC2 includes two case units CU2, CU3 such that pickfacePCKFC2 is larger than PCKFC1. In other aspects the pickfaces PCKFC1,PCKFC2 have any suitable size and include any suitable number of caseunits. As may also be realized, while two pickfaces PCKFC1, PCKFC2 areillustrated being held on the load handling device LHDA in other aspectsthe load handling device LHDA holds any suitable number of pickfacessuch as more than two or less than two. The arrangement of the pickfacesPCKFC1, PCKFC2 (and the case units/totes therein) are, in one aspect,arranged on an inbound or outbound lift 150A, 150B according to apredetermined sequence. As an example, the pickfaces PCKFC1, PCKFC2 areakin to one or more of pickfaces 5, 7 described above.

In accordance with one or more aspects of the disclosed embodiment, alift includes at least one load handling device configured so as toreciprocate along a lift axis, the load handling device including aframe forming a payload section with a payload support surface having acommon elevation configured to hold one or more pickfaces at the commonelevation of the payload support surface; at least one transfer armmovably mounted to the frame; and a drive section connected to the loadhandling device and being configured to move the load handling devicealong the lift axis; wherein the one or more pickfaces carried in unisonby the payload support surface of the at least one load handling device,define an order sequence of pickfaces on the at least one load handlingdevice according to a predetermined case out order sequence of mixedcases.

In accordance with one or more aspects of the disclosed embodiment, thelift further includes a controller connected to the drive section, thecontroller being configured to effect the defined order sequence ofpickfaces on the at least one load handling device according to apredetermined case out order sequence of mixed cases.

In accordance with one or more aspects of the disclosed embodiment, atleast one pickface of the one or more pickfaces is a multiple case unitpickface.

In accordance with one or more aspects of the disclosed embodiment, thelift is configured to place the one or more pickfaces in accordance witha predetermined case out order sequence.

In accordance with one or more aspects of the disclosed embodiment, theat least one transfer arm is common to two or more pickfaces such thattransfer arm is configured to hold the two are more pickfaces adjacentone another.

In accordance with one or more aspects of the disclosed embodiment, theat least one transfer arm comprises two independently operable transferarms configured to individually transfer pickfaces to and from the loadhandling device.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device comprises two independently operableload handling device configured to individually transfer pickfaces.

In accordance with one or more aspects of the disclosed embodiment, theload handling device further comprising a justification member disposedwithin the payload section wherein the controller is configured tocontrol a combined movement of the justification member and the transferarm to effect the sorting of the two or more case pickfaces carried inthe payload section.

In accordance with one or more aspects of the disclosed embodiment, thelift further includes a justification member connected to the drivesection and the controller, the justification member being movablymounted to the frame where the transfer arm and the justification memberare each independently movable relative to each other.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to control the drive section and effectmovement of the justification member and transfer arm so that theon-the-fly sortation is effected by retention of at least one of the twoor more pickfaces within the payload section while at least another ofthe two or more pickfaces is transferred to or from the payload section.

In accordance with one or more aspects of the disclosed embodiment, thelift is a high speed lift having a pickface transfer transaction ratesubstantially equal to a pickface transfer transaction rate of anautonomous transport vehicle transferring pickfaces to the reciprocatinglift.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device is mounted on a mast so as toreciprocate along a length of the mast.

In accordance with one or more aspects of the disclosed embodiment, anautomated storage and retrieval system lift includes a frame; at leastone payload carriage having a carriage frame with a drive axis andforming a payload section configured to hold one or more payload items,and multiple independent degree of freedom transfer arms arranged on thefirst payload axis so as to move along a first payload axis transverseto the drive axis, the multiple independent degree of freedom transferarms being disposed at least partly within the payload section; andwherein the multiple independent degree of freedom transfer arms and thepayload section are configured to effect an on-the-fly sorting of theone or more payload items carried in the payload section.

In accordance with one or more aspects of the disclosed embodiment, theat least one payload carriage further comprises a justification memberdisposed within the payload section so as to move along a second payloadaxis transverse to the first payload axis.

In accordance with one or more aspects of the disclosed embodiment, thelift further including a controller connected to the justificationmember and the at least one transfer arm, the controller beingconfigured to control a combined movement of the justification memberand the at least one transfer arm to effect an on-the-fly sorting of theone or more payload items carried in the payload section.

In accordance with one or more aspects of the disclosed embodiment, thejustification member and the at least one transfer arm are eachindependently movable relative to each other.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to effect movement of the justification memberand the at least one transfer arm so that the justification member isinserted between two of the one or more payload items to cause aphysical separation of the two of the one or more payload items.

In accordance with one or more aspects of the disclosed embodiment, thejustification member is configured to bi-directionally move the one ormore payload items along the second axis within the payload section.

In accordance with one or more aspects of the disclosed embodiment,wherein the controller is configured to control movement of thejustification member and the at least one transfer arm so that sortingis effected by retention of at least one of the one or more payloaditems within the payload section while at least another of the one ormore payload items is transferred to or from the payload section.

In accordance with one or more aspects of the disclosed embodiment, theat least one payload carriage comprises two individually operablepayload carriages arranged side by side on the mast so as to travelalong the mast independently of each other.

In accordance with one or more aspects of the disclosed embodiment, theat least one transfer arm includes multiple payload holding locationsarranged to hold payloads in at least a side by side arrangement toeffect a simultaneous transfer of the payloads to and from the at leastone transfer arm.

In accordance with one or more aspects of the disclosed embodiment, thetransfer arm includes a plurality of payload support tines configuredfor a pass through transfer of payloads to a payload holding location ofa storage and retrieval system.

In accordance with one or more aspects of the disclosed embodiment, thedrive axis comprises a common mast on which the multiple independentdegree of freedom transfer arms are arranged.

In accordance with one or more aspects of the disclosed embodiment, astorage and retrieval system includes at least one transfer stationconfigured to hold at least one pickface; at least one bot configured totransfer the at least one pickface to and from the at least one transferstation; at least one load handling device mounted so as to reciprocatealong a lift axis, the at least one load handling device being incommunication with the at least one transfer station and including aframe forming a payload section with a payload support surface having acommon elevation configured to hold one or more pickfaces at the commonelevation of the payload support surface; at least one transfer armmovably mounted to the frame; a drive section connected to the at leastone load handling device and being configured to move the load handlingdevice along the lift axis; wherein the one or more pickfaces carried inunison by the payload support surface of the at least one load handlingdevice, define an order sequence of pickfaces on the at least one loadhandling device according to the predetermined case out order sequenceof differently configured pickfaces.

In accordance with one or more aspects of the disclosed embodiment, thestorage and retrieval system further including a controller connected tothe drive section, the controller being configured to effect the definedorder sequence of pickfaces on the at least one load handling deviceaccording to a predetermined case out order sequence between thedifferently configured pickfaces.

In accordance with one or more aspects of the disclosed embodiment, atleast one pickface of the one or more pickfaces is a multiple case unitpickface.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device is configured to place the one or morepickfaces in accordance with a predetermined case out order sequence.

In accordance with one or more aspects of the disclosed embodiment, theat least one transfer arm is common to two or more pickfaces such thattransfer arm is configured to hold the two are more pickfaces adjacentone another.

In accordance with one or more aspects of the disclosed embodiment, theat least one transfer arm comprises two independently operable transferarms configured to individually transfer pickfaces to and from the atleast one load handling device.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device comprises two independently operableload handling device configured to individually transfer pickfaces.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device further comprising a justificationmember disposed within the payload section wherein the controller isconfigured to control a combined movement of the justification memberand the transfer arm to effect the sorting of the two or more casepickfaces carried in the payload section.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device further includes a justificationmember connected to the drive section and the controller, thejustification member being movably mounted to the frame where thetransfer arm and the justification member are each independently movablerelative to each other.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to control the drive section and effectmovement of the justification member and transfer arm so that theon-the-fly sortation is effected by retention of at least one of the twoor more pickfaces within the payload section while at least another ofthe two or more pickfaces is transferred to or from the payload section.

In accordance with one or more aspects of the disclosed embodiment, theat least one load handling device is a high speed lift having a pickfacetransfer transaction rate substantially equal to a pickface transfertransaction rate of an autonomous transport vehicle transferringpickfaces to the at least one load handling device.

In accordance with one or more aspects of the disclosed embodiment, anorder sequence of the differently configured pickfaces is independentfrom an order sequence of pickfaces at the transfer station.

In accordance with one or more aspects of the disclosed embodiment, amethod includes picking a pickface with a common platform of a lift, thepickface being in an ordered sequence on the common platform; andsubstantially simultaneously placing the pickface, with the commonplatform, in the ordered sequence at an outbound pickface holdinglocation.

In accordance with one or more aspects of the disclosed embodiment, thepickface includes mixed case units.

In accordance with one or more aspects of the disclosed embodiment, thepickface includes more than one different pickface.

In accordance with one or more aspects of the disclosed embodiment, thepickface is picked from a common level of a pickface holding location.

In accordance with one or more aspects of the disclosed embodiment, thepickface is picked from multiple levels of pickface holding locations.

In accordance with one or more aspects of the disclosed embodiment, amethod includes picking more than one pickface with a common platform ofa lift; and effecting, with the lift, an on-the-fly sortation of themore than one pickface.

In accordance with one or more aspects of the disclosed embodiment, theon-the-fly sortation of the more than one pickface includes traversing,with the common platform, a stack of pickface holding locations in acommon direction.

In accordance with one or more aspects of the disclosed embodiment, amethod includes picking at least one pickface with a common platform ofa lift; and placing, with the lift, the at least one pickface at anoutbound pickface holding location in one offload step, where the atleast one pickface has a sorted arrangement at offload.

In accordance with one or more aspects of the disclosed embodiment, theat least one pickface includes mixed case units.

In accordance with one or more aspects of the disclosed embodiment, theat least one pickface includes more than one different pickface.

In accordance with one or more aspects of the disclosed embodiment, theat least one pickface is picked from a common level of a pickfaceholding location.

In accordance with one or more aspects of the disclosed embodiment, theat least one pickface is picked from multiple levels of pickface holdinglocations.

In accordance with one or more aspects of the disclosed embodiment, alift includes at least one load handling device mounted so as toreciprocate along a lift axis, the load handling device including aframe forming a payload section with a common payload support platformconfigured to hold one or more pickfaces on the common payload supportplatform; at least one transfer arm movably mounted to the frame; adrive section connected to the load handling device and being configuredto move the load handling device along the lift axis; and a controllerconnected to the drive section and being configured to effect pickingmore than one pickface with the common payload support platform, and anon-the-fly sortation of the more than one pickface with the commonpayload support platform.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to effect picking of the more than onepickface, with the common payload support platform, in an orderedsequence and placing the one or more pickfaces, with the common payloadsupport platform, in the ordered sequence at an outbound pickfaceholding location.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to effect the on-the-fly sortation of the morethan one pickface where the common payload support platform traverses astack of pickface holding locations in a common direction.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to effect placement of more than one pickfaceat an outbound pickface holding location in one offload step, where themore than one pickface has a sorted arrangement at offload.

It should be understood that the foregoing description is onlyillustrative of the aspects of the disclosed embodiment. Variousalternatives and modifications can be devised by those skilled in theart without departing from the aspects of the disclosed embodiment.Accordingly, the aspects of the disclosed embodiment are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims. Further, the mere fact thatdifferent features are recited in mutually different dependent orindependent claims does not indicate that a combination of thesefeatures cannot be advantageously used, such a combination remainingwithin the scope of the aspects of the invention.

What is claimed is:
 1. An automated storage and retrieval system liftcomprising: a frame; and at least one payload carriage having a carriageframe with a drive axis and forming a payload section configured to holdone or more pickfaces, and at least one independent degree of freedomtransfer arm arranged on a first payload axis so as to move along firstpayload axis transverse to the drive axis, the at least one independentdegree of freedom transfer arm being disposed at least partly within thepayload section; wherein the at least one independent degree of freedomtransfer arm and the payload section are configured to effect an.on-the-fly sorting of the one or more pickfaces carried in the payloadsection.
 2. The automated storage and retrieval system lift of claim 1,wherein the at least one independent degree of freedom transfer arm iscommon to two or more pickfaces such that at least one independentdegree of freedom transfer arm is configured to hold the two are morepickfaces adjacent one another.
 3. The automated storage and retrievalsystem lift of claim 1, wherein the automated storage and retrievalsystem lift is a high speed lift having a pickface transfer transactionrate substantially equal to a pickface transfer transaction rate of anautonomous transport vehicle transferring pickfaces to the automatedstorage and retrieval system lift.
 4. The automated storage andretrieval system lift of claim 1, wherein the at least one payloadcarriage is mounted on a mast so as to reciprocate along a length of themast.
 5. The automated storage and retrieval system lift of claim 1,wherein the at least one independent degree of freedom transfer armincludes at least one pickface holding location arranged to holdpickfaces in at least a side by side arrangement to effect asimultaneous transfer of the pickfaces to and from the at least oneindependent degree of freedom transfer arm.
 6. The automated storage andretrieval system lift of claim 1, wherein the at least one independentdegree of freedom transfer arm includes a plurality of pickface supporttines configured for a pass through transfer of pickfaces to a pickfaceholding location of a storage and retrieval system.
 7. The automatedstorage and retrieval system lift of claim 1, wherein the drive axiscomprises a common mast on which the at least one independent degree offreedom transfer arm is arranged.
 8. An automated storage and retrievalsystem lift comprising: a frame; and at least one payload carriagehaving a carriage frame with a drive axis and forming payload sectionconfigured to hold one or more pickfaces, and at least one independentdegree of freedom transfer arm arranged on a first payload axis so as tomove along a first payload axis transverse to the drive axis, the atleast one independent degree of freedom transfer arm being disposed atleast partly within the payload section.
 9. The automated storage andretrieval system lift of claim 8, wherein the at least one independentdegree of freedom transfer arm is common to two or more pickfaces suchthat at least one independent degree of freedom transfer arm isconfigured to hold the two are more pickfaces adjacent one another. 10.The automated storage and retrieval system lift of claim 8, wherein theautomated storage and retrieval system lift is a high speed lift havinga pickface transfer transaction rate substantially equal to a pickfacetransfer transaction rate of an autonomous transport vehicletransferring pickfaces to the automated. storage and. retrieval systemlift.
 11. The automated storage and retrieval system lift of claim 8,wherein the at least one payload carriage is mounted on a mast so as toreciprocate along a length of the mast.
 12. The automated storage andretrieval system lift of claim 8, wherein the at least one independentdegree of freedom transfer arm includes at least one pickface holdinglocation arranged to hold pickfaces in at least a side by sidearrangement to effect a simultaneous transfer of the pickfaces to andfrom the at least one independent degree of freedom transfer arm. 13.The automated storage and retrieval system lift of claim 8, wherein theat least one independent degree of freedom transfer arm includes aplurality of pickface support tines configured for a pass throughtransfer of pickfaces to a pickface holding location of a storage andretrieval system.
 14. The automated storage and retrieval system lift ofclaim 8, wherein the drive axis comprises a common mast on which the atleast one independent degree of freedom transfer arm is arranged.
 15. Amethod comprising: providing a frame of an automated storage andretrieval lift; providing at least one payload carriage having acarriage frame with a drive axis and forming a payload sectionconfigured to hold one or more pickfaces, and at least one independentdegree of freedom transfer arm arranged on a first payload axis so as tomove along a first payload axis transverse to the drive axis, the atleast one independent degree of freedom transfer arm being disposed atleast partly within the payload section; effecting an on-the-flysorting, with the at least one independent degree of freedom transferarm and the payload section, of the one or more pickfaces carried in thepayload section.
 16. The method of claim 15, wherein the at least oneindependent degree of freedom transfer arm is common to two or morepickfaces for holding the two are more pickfaces adjacent one another.17. The method of claim 15, wherein the automated storage and retrievalsystem lift is a high speed lift having a pickface transfer transactionrate substantially equal to a pickface transfer transaction rate of anautonomous transport vehicle transferring pickfaces to the automatedstorage and retrieval system lift.
 18. The method of claim 15, furthercomprising mounting the at least one payload carriage on a mast so as toreciprocate along a length of the mast.
 19. The method of claim 15,wherein the at least one independent degree of freedom transfer armincludes at least one pickface holding location arranged to holdpickfaces in at least a side by side arrangement, the method furthercomprising effecting a simultaneous transfer of the pickfaces to andfrom the at least one independent degree of freedom transfer arm. 20.The method of claim 15, wherein the at least one independent degree offreedom transfer arm includes a plurality of pickface support tinesconfigured for a pass through transfer of pickfaces to a pickfaceholding location of a storage and retrieval system.
 21. The method ofclaim 15, wherein the drive axis comprises a common mast on which the atleast one independent degree of freedom transfer arm is arranged.